Burner control

• US 8,956,152 B2
• Filed: 11/20/2012
• Issued: 02/17/2015
• Est. Priority Date: 05/31/2006
• Status: Active Grant

• Current Assignee: Beckett Gas Inc.
• Original Assignee: Beckett Gas Inc.
• Inventors: Cook, Richard D.
• Primary Examiner(s): Hu, Kang
• Assistant Examiner(s): NAMAY, DANIEL ELLIOT
• Application Number:
  US13/682,097
• Publication Number:
  US 20130081581A1
• Time in Patent Office: 819 Days
• Field of Search: 431/6, 431/78, 431/15, 431/14, 431/27, 122/14.1, 122/14.2, 122/14.22, 237/8.A, 237/81, 236/1.A, 236/1.H, 236/21.R, 236/11, 236/15.BB, 236/15.BR, 236/15.C, 700/299, 110/185, 110/186, 110/187
• US Class Current: 431/6
• CPC Class Codes: F23N 2223/08 Microprocessor; Microcomputer
• CPC Class Codes: F23N 2225/16 burner temperature
• CPC Class Codes: F23N 2231/02 using electric energy accumulators
• CPC Class Codes: F23N 5/107 using mechanical means, e.g. safety valves
• CPC Class Codes: F23N 5/14 using thermo-sensitive resistors
• CPC Class Codes: F23N 5/242 using electronic means
• CPC Class Codes: F24H 15/104 Inspection; Diagnosis; Trial operation
• CPC Class Codes: F24H 15/20 characterised by control inputs
• CPC Class Codes: F24H 15/25 Temperature of the heat-generating means in the heater
• CPC Class Codes: F24H 15/254 Room temperature
• CPC Class Codes: F24H 15/36 of burners
• CPC Class Codes: F24H 15/421 using pre-stored data
• CPC Class Codes: F24H 9/2035 using fluid fuel

Abstract

A fuel-fired water heater is shut down when a predicted steady state combustion chamber temperature is below a known threshold. The predicted steady state temperature is based on combustion chamber temperatures during heat up of the burner and appliance.

Claims

1. A method for disabling a burner in a water heater before the water heater produces carbon monoxide in excess of allowable levels due to restrictions or blockages in the combustion system, the method comprising the steps of:

a) providing a controller;

b) storing an array of target temperatures accessible by said controller, each target temperature having a corresponding elapsed operational time for reaching said temperature, longer stored elapsed operational times having higher stored temperatures up to a maximum temperature;

c) using an ignition device to ignite a burner in a combustion chamber to commence a heating cycle and determining whether said burner is lit, said ignited burner heating water in said water heater;

d) upon determining said burner is lit and while said burner continues to be lit, using a sensor to check said combustion chamber temperature at one of said elapsed operational times and comparing said temperature with the associated target temperature and;

e) continue comparing received sensed temperatures to target temperatures corresponding to subsequent elapsed operational times until either a water set-point temperature is reached and said burner is shut down, or one of said temperatures is below said target temperature at a corresponding elapsed operational time for a predetermined number of cycles whereupon operation of said burner is disabled.

2. The method of claim 1 wherein a plurality of combustion chamber temperatures is sensed and compared to stored temperatures over several time intervals and said burner is disabled if a predetermined number of said plurality of said temperatures are below said target temperatures.

3. The method of claim 2 wherein said temperature is sensed by a sensor mounted on a surface of said combustion chamber.

4. The method of claim 2 further comprising the step of detecting ambient temperature and using the detected ambient temperature to adjust said target temperatures or said combustion chamber temperature when a target temperature is being compared to a sensed temperature.

5. The method of claim 1 wherein a succeeding detected temperature is compared to a preceding detected temperature to determine whether the temperature in said combustion chamber is increasing.

6. The method of claim 1 wherein a carbon monoxide detector is connected to said combustion system and said burner is disabled upon receiving a predetermined signal from said carbon monoxide detector.

10. The method of claim 1 wherein said controller includes a microprocessor and a memory for storing said array of target temperatures.

11. The method of claim 1 wherein said controller includes a memory for storing said array of target temperatures.

12. The method of claim 10 further comprising the step of powering said microprocessor with a thermopile.

7. As method for disabling a burner that forms part of a combustion apparatus in a water heater when the combustion apparatus becomes restricted or partially blocked, the method comprising the steps of:

a) providing a controller and storing data related to the normal temperature operating range of a burner in a combustion chamber;

b) using an ignition device to ignite said burner to begin a heating cycle during which water in said water tank is heated, said ignited burner heating water in said water heater;

c) determining whether said burner is lit and upon determining said burner is lit and while said burner continues to be lit, checking the temperature of said combustion apparatus after a predetermined interval of time using a sensor coupled to said controller;

d) using said controller to at least partially determine whether the checked temperature is in a normal operating range of said combustion apparatus; and

e) continue using said controller to at least partially determine whether the checked temperature is in a normal operating range of said combustion apparatus until either a water set-point temperature is reached and said burner is shut down, or a checked temperature is not in a normal operating range for a predetermined number of cycles whereupon operation of said burner is disabled.

8. The method of claim 7 further comprising the step of monitoring ambient temperature and using said monitored ambient temperature in determining if said detecting temperature is below said normal operating range of said water heater.

9. The method of claim 8 further comprising the step of monitoring the temperature of water in said water heater and using said water temperature to arrive at the normal operating range of said water heater.

13. The method of claim 7 further comprising the step of powering said controller using a thermopile.

14. The method of claim 7 wherein said controller includes a microprocessor.