Furnace control with safety circuit and non-volatile memory

• US 9,500,366 B2
• Filed: 12/05/2013
• Issued: 11/22/2016
• Est. Priority Date: 12/05/2013
• Status: Active Grant

• Current Assignee: International Controls and Measurements Corporation
• Original Assignee: International Controls and Measurements Corporation
• Inventors: Kadah, Andrew S., Pan, Weidong, Freer, Benjamin A.
• Primary Examiner(s): Barnes-Bullock, Crystal J
• Application Number:
  US14/097,978
• Publication Number:
  US 20150159887A1
• Time in Patent Office: 1,083 Days
• US Class Current: 1/1
• CPC Class Codes: F23N 2223/04 Memory
• CPC Class Codes: F23N 2223/08 Microprocessor; Microcomputer
• CPC Class Codes: F23N 2225/04 pressure
• CPC Class Codes: F23N 2225/08 temperature
• CPC Class Codes: F23N 2231/10 for component failures
• CPC Class Codes: F23N 2231/20 Warning devices
• CPC Class Codes: F23N 5/242 using electronic means
• CPC Class Codes: F23Q 7/24 Safety arrangements
• CPC Class Codes: F24D 19/1084 for air heating systems
• CPC Class Codes: F24D 5/02 operating with discharge of hot air into the space or area to be heated
• CPC Class Codes: F24H 15/104 Inspection; Diagnosis; Trial operation
• CPC Class Codes: F24H 15/116 Disabling the heating means in response thereto
• CPC Class Codes: F24H 15/20 characterised by control inputs
• CPC Class Codes: F24H 15/242 Pressure
• CPC Class Codes: F24H 15/254 Room temperature
• CPC Class Codes: F24H 15/345 Control of fans, e.g. on-off control control of fans of heat pump units F24H15/375
• CPC Class Codes: F24H 15/36 of burners
• CPC Class Codes: F24H 15/395 Information to users, e.g. alarms
• CPC Class Codes: F24H 15/421 using pre-stored data
• CPC Class Codes: F24H 15/486 using timers
• CPC Class Codes: F27B 9/40 : Arrangements of controlling or monitoring devices
• CPC Class Codes: G05B 15/02 : electric

Abstract

A furnace controller circuit includes a microprocessor with input ports and output ports including ports to issue control signals for actuation of inducer, gas burner, and furnace blower. A temperature-actuated limit switch commences a furnace shut-down sequence when the temperature of the furnace heat exchanger exceeds a predetermined limit temperature, and then resets to permit a turn-on sequence. An LED visible fault indicator is coupled to the microprocessor to provide visible fault messages. A non-volatile memory device coupled with the microprocessor is operative to store fault indications when present. In the event of power restoration after power failure, the limit switch status and other fault status are maintained. A lockout period is computed based on length of furnace run time until fault and recent fault history. Limit switch and other safety faults are recorded and these can be weighted and ranked based on age of each fault occurrence. The stored fault data can be used to identify erratic furnace operations, such as short cycling.

Claims

1. In a fuel-fed furnace of the type which comprises

a burner supplied with fuel and which produces a flame;

a heat exchanger in which the flame passes through a combustion air path of a heat exchanger to an exhaust;

a blower which forces a flow or return air from a comfort space through a comfort air path of said heat exchanger, and thence through a ductwork to supply heated air to said comfort space;

a source of AC power;

a controller circuit coupled to said source of AC power and which controllably actuates said burner and said blower to effect a turn-on sequence in response to a call for heat from an associated thermostat, and to effect a shut down sequence when said call for heat is satisfied, said controller circuit including a microcontroller having a plurality of input ports and a plurality of output ports including ports to issue control signals for actuation of said burner and for said blower, said controller circuit further including a non-volatile memory device coupled with said microcontroller and operative to store a fault indication when present;

at least one temperature actuated limit switch effective to commence said shut-down sequence when the temperature of said heat exchanger exceeds a predetermined limit temperature, and which resets to permit said turn-on sequence after said shut-down sequence;

the improvement wherein

said microcontroller is configured to so as to store a history of actuations of said limit switch; and

wherein said microcontroller is operative upon an actuation of said limit switch to establish a lock-out condition to preclude said furnace from effecting said start-up sequence for a period of time depending upon a stored history of actuations of said limit switch;

said microcontroller being operative to monitor time remaining in said period of time of said lock-out condition;

said microcontroller being suitably programmed to process the stored history of actuations of the limit switch;

wherein

said controller circuit includes a rechargeable DC supply, sufficient to power said microprocessor for a limited period of time in an absence of power provided from said source of AC power; and

wherein

said microcontroller is operative, when absence of AC power occurs, to continue to monitor time remaining in the period of time of the lock-out condition; and

upon restoration of power to said source of AC power, if time remains in said period of time of the lock-out condition, to continue said lock-out condition until the time that remains in said period of time thereof has expired.

2. In HVAC equipment of the type which comprises

a source of a heated or chilled medium;

a heat exchanger in which the heated or chilled medium passes;

a blower forces a flow of return air from a comfort space through a comfort air path of said heat exchanger, and thence through a ductwork to supply heated or chilled air to said comfort space;

a controller circuit coupled to a source of AC power and which controllably actuates said source of heated or chilled medium and said blower to effect a turn-on sequence in response to a call for heat or cooling from an associated thermostat, and to effect a shut down sequence when said call for heat or cooling is satisfied, said controller circuit including a microprocessor having a plurality of input ports and a plurality of output ports including ports to issue control signals for actuation of said source of heated or chilled medium and for said blower;

a fault-actuated safety switch effective to commence said shut-down sequence when a safety parameter in said HVAC equipment exceeds a predetermined limit value, and which resets to permit said turn-on sequence after said shut-down sequence;

and a visible fault indicator coupled to one of the outputs of said microprocessor and operative to provide a visible fault indication in response to actuation of said safety switch;

the improvement wherein said microprocessor establishes a wait time L after each opening of the safety switch during a given call for heat or cooling, in which after the safety switch resets the controller circuit waits for a time period equal to said wait time L to expire before re-initiating said turn-on sequence;

wherein the microprocessor measures a time duration T from each initiation of the turn-on sequence until an opening of said safety switch; and

the microprocessor calculates said wait time L according to an algorithm in which the wait time L is inversely related to the time duration T, such that the wait time L is greater for smaller values of the time duration T; and

in which the value of the wait time L is increased for successive openings of the safety switch during a given call for heat or cooling.

3. The HVAC equipment according to claim 2 wherein said microprocessor is suitably programmed to set the wait time L to a predetermined initial value when a call for heat is not present.

4. The HVAC equipment according to claim 3 wherein said microprocessor sets said initial value as L=0.

5. The HVAC equipment according to claim 2 wherein said microprocessor is programmed to calculate said wait time L according to a formulation

6. The HVAC equipment according to claim 5 wherein K=0.75;

T₁=4096; and

T_max=4600, all in time units of seconds.

7. In a fuel-fed furnace of the type which comprises

a burner supplied with fuel and which produces a flame;

a heat exchanger in which the flame passes through a combustion air path of a heat exchanger to an exhaust;

a blower which forces a flow of return air from a comfort space through a comfort air path of said heat exchanger, and thence through a ductwork to supply heated air to said comfort space;

a controller circuit which controllably actuates said burner and said blower to effect a turn-on sequence in response to a call for heat from an associated thermostat, and to effect a shut down sequence when said call for heat is satisfied, said controller circuit including a microprocessor having a plurality of input ports and a plurality of output ports including ports to issue control signals for actuation of said burner and for actuation of said blower, said controller circuit further including a non-volatile memory device coupled with said microprocessor and operative to store a fault indication when present;

at least one temperature-actuated safety switch effective to commence said shut-down sequence when the temperature of said heat exchanger exceeds a predetermined limit temperature, and which resets to permit said turn-on sequence after said shut-down sequence, the temperature-actuated safety switch being coupled to an input port of said microprocessor, and the latter being configured to ascertain the presence of a temperature fault based on actuation of said temperature-actuated safety switch;

further comprising a pressure detector and a flame presence detector, each coupled with a respective input port of said microprocessor, the latter being configured to ascertain the presence of a pressure fault and a flame presence fault,

a pushbutton switch coupled to an input port of the microprocessor;

a visible fault indicator coupled to one of the output ports of said microprocessor and operative to provide a visible fault message in response to a query executed by pressing said pushbutton switch; and

the improvement wherein said microprocessor is configured to store a history of the occurrences of each of said temperature fault, said pressure fault, and said flame presence fault, including, for each said occurrence, type of fault and time of occurrence of fault, and to rank each type of fault according to an algorithm, in which each type of fault has a predetermined weight factor W stored in said microprocessor, and with said algorithm computing the rank for each fault based on age of the respective fault records for said type of fault and also based on the number of said fault records for each said type of fault occurrence; and

said visible fault indicator presenting said fault messages upon an actuation of said pushbutton switch, in an order based on the rankings of said types of fault and as computed by said microprocessor according to said algorithm.

8. The fuel-fed furnace according to claim 7, wherein each of said types of fault has a different value for its associated predetermined weight factor.

9. The fuel-fed furnace according to claim 7, wherein said microprocessor increments a counter for each call for heat satisfied by said furnace to maintain a count value for each call for heat, and the microprocessor maintains said history of occurrences of said faults, for each fault the type of fault and the count value when said fault occurred, such that the ages of occurrences of faults are maintained in terms of furnace cycles.

10. In a fuel-fed furnace of the type which comprises:

a burner supplied with fuel and which produces a flame;

a heat exchanger in which the flame passes through a combustion air path of a heat exchanger to an exhaust;

a blower which forces a flow of return air from a comfort space through a comfort air path of said heat exchanger, and thence through ductwork to supply heated air to said comfort space;

a controller circuit coupled to said burner and said blower, and including a microcontroller having a plurality of input ports and a plurality of output ports, and a memory device capable of storing a plurality of fault occurrences of a plurality of fault types, when present;

a plurality of fault sensors operatively coupled to at least said burner, said heat exchanger, and said blower to report a respective fault type when the operating performance of the associated one of said burner, said heat exchanger, and said blower is outside a respective limit, said fault sensors each being coupled to a respective one of the input ports of said microcontroller;

a push button coupled to one input port of said microcontroller and capable of signalling said microcontroller each time the push button is tapped;

a visible fault indicator being coupled to an output port of said microcontroller and being operative to display a message according to each given fault type, when present, in response to a predetermined pattern of taps on said push button.

11. The fuel fed furnace according to claim 10, wherein the fault message for each fault type is displayed in response to a different respective pattern of taps.

12. The fuel fed furnace according to claim 10, wherein the fault message for each fault type is displayed in sequence according to a computed priority of the fault types.

13. The fuel fed furnace according to claim 10, wherein the microcontroller is operative to reset the memory device that is capable of storing a plurality of fault occurrences of a plurality of fault types in response to said push button being actuated for at least a predetermined length of time.

14. The fuel fed furnace according to claim 13, wherein a tap is effected by actuating said push button for a period of less than one second, and said the resetting of said memory device is effected by actuating said push button for said predetermined length of time of more than one second.