Heating apparatus and method of detecting a short-cycling condition

• US 7,590,470 B2
• Filed: 11/29/2004
• Issued: 09/15/2009
• Est. Priority Date: 01/23/2004
• Status: Expired due to Fees

• Current Assignee: AOS Holding Company (A O Smith Corporation)
• Original Assignee: AOS Holding Company (A O Smith Corporation)
• Inventors: Basheer, Sohail, Caves, Andy, Holliman, Howard
• Primary Examiner(s): Jarrett; Ryan A
• Application Number:
  US10/998,418
• Publication Number:
  US 20050177281A1
• Time in Patent Office: 1,751 Days
• Field of Search: 700/12, 700/14, 700/26, 700/32, 700/33, 700/153, 700/204, 700/205, 700/207, 700/276, 700/275, 700/299, 700/300, 700/306, 700/278
• US Class Current: 700/278
• CPC Class Codes: F23N 1/00 Regulating fuel supply
• CPC Class Codes: F23N 2241/04 Heating water
• CPC Class Codes: F23N 5/00 Systems for controlling combustion regulating fuel supply F23N1/00, regulating air supply or draught F23N3/00

Abstract

The invention includes a controller for a boiler and a method of detecting a short-cycling condition of the boiler. The controller includes a user interface module, a short-cycling detection module, and an adjustment module. The method includes the acts of detecting when the boiler is in a short-cycling condition and introducing delays at various operational points throughout a heating process.

Claims

1. A method of heating an enclosure with a boiler, the method comprising:

generating a threshold for an on state of the boiler;

generating a threshold for an off state of the boiler;

determining if the boiler is in a short-cycling condition based on a plurality of transitions between the off state and the on state; and

if the boiler is in the short-cycling condition, automatically delaying a next on state for a predetermined time period.

2. The method of claim 1 wherein the boiler is in the short-cycling condition when the boiler transitions from the off state to the on state at least thirty times in one hour.

3. The method of claim 1 wherein a user of the boiler performs the acts of generating the thresholds for the on state and the off state of the boiler.

4. The method of claim 1 wherein the predetermined time period is in the range of about 100 seconds to about 200 seconds.

5. The method of claim 1 wherein the predetermined time period is in the range of about 165 seconds to about 185 seconds.

6. A method of heating an enclosure with a boiler, the method comprising:

generating a threshold for an on state for each stage of the boiler;

generating a threshold for an off state for each of the stages;

detecting that one of the stages is in a short-cycling condition based on a number of transitions between the off state and the on state for that stage;

determining which stage is in the short-cycling condition; and

automatically delaying the on state of the stage following the stage in which the short-cycling condition was detected for a predetermined time period.

7. The method of claim 6 wherein the boiler is in the short-cycling condition when one of the stages transitions from the off state to the on state at least thirty times in one hour.

8. The method of claim 6 wherein a user of the boiler performs the acts of generating the thresholds for the on state and the off state of the stages.

9. The method of claim 6 wherein the predetermined time period is in the range of about 10 seconds to about 185 seconds.

10. The method of claim 6 wherein the predetermined time period is in the range of about 186 seconds to about 500 seconds.

11. A boiler including a controller, the controller comprising:

a user interface module operable to receive an input;

a short-cycling detection module operable to detect when the boiler is in a short-cycling state based on a plurality of transitions between an off state and an on state of the boiler; and

an adjustment module operable to adjust at least one operational parameter of the boiler to correct the short-cycling condition.

12. The controller of claim 11 wherein the input includes a temperature value.

13. The controller of claim 11 wherein the at least one operational parameter is related to time.

14. The controller of claim 11 wherein the at least one operational parameter is related to temperature.

15. The controller of claim 11 wherein the short-cycling detection module is operable to determine a stage of the boiler in which the short-cycling state occurred.

16. The controller of claim 15 wherein the adjustment module is operable to delay the start of the stage that follows the stage in which the short-cycling state occurred.

17. The controller of claim 11 wherein the boiler is in the short-cycling state when the boiler transitions from a predetermined off state to a predetermined on state at least thirty times in one hour.

18. A boiler comprising:

a burner having a plurality of stages; and

a controller operable to transmit commands to the burner, the commands operable to instruct the burner to operate at least one of the stages, the controller including

a detection module operable to detect when the boiler is in a short-cycling state based on a number of transitions between an off state and an on state of the boiler and to detect the stage in which the short-cycling state occurred, and

an adjustment module operable to delay the start of any stage that follows the stage in which the short-cycling state occurred.

19. The boiler of claim 18 wherein the controller further comprises a user interface module operable to receive temperature thresholds for the on state and the off state of the boiler.

20. The boiler of claim 19 wherein the boiler is in the short-cycling state when the boiler transitions from the off state to the on state at least thirty times in one hour.

21. The boiler of claim 18 wherein each stage includes a plurality of heat sequences.

22. The boiler of claim 21 wherein the detection module is operable to determine the heat sequence in which the short-cycling state occurred, and wherein the adjustment module is operable to delay the start of the heat sequence that follows the heat sequence in which the short-cycling state occurred.

23. The boiler of claim 18 wherein the delay of the start of the stage that follows the stage in which the short-cycling state occurred is in the range of about 10 seconds to about 185 seconds.

24. The boiler of claim 18 wherein the delay of the start of the stage that follows the stage in which the short-cycling state occurred is in the range of about 186 seconds to about 500 seconds.