EP1077821B1 - Method and apparatus for regulating heater cycles to improve fuel efficiency - Google Patents
Method and apparatus for regulating heater cycles to improve fuel efficiency Download PDFInfo
- Publication number
- EP1077821B1 EP1077821B1 EP98913036A EP98913036A EP1077821B1 EP 1077821 B1 EP1077821 B1 EP 1077821B1 EP 98913036 A EP98913036 A EP 98913036A EP 98913036 A EP98913036 A EP 98913036A EP 1077821 B1 EP1077821 B1 EP 1077821B1
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- EP
- European Patent Office
- Prior art keywords
- energy value
- boiler
- outflow
- burner
- sensor
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
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- 238000000034 method Methods 0.000 title claims abstract description 8
- 239000000446 fuel Substances 0.000 title claims abstract description 7
- 230000001105 regulatory effect Effects 0.000 title 1
- 238000010438 heat treatment Methods 0.000 claims abstract description 41
- 238000010304 firing Methods 0.000 claims abstract description 32
- 238000003915 air pollution Methods 0.000 claims abstract description 4
- 230000008859 change Effects 0.000 claims description 15
- 238000012546 transfer Methods 0.000 claims description 9
- 239000012530 fluid Substances 0.000 claims description 8
- 238000012544 monitoring process Methods 0.000 claims description 6
- 230000007423 decrease Effects 0.000 claims description 5
- 230000004044 response Effects 0.000 claims description 3
- 230000035945 sensitivity Effects 0.000 claims description 3
- 230000003044 adaptive effect Effects 0.000 claims 2
- 238000013459 approach Methods 0.000 claims 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 44
- 238000009434 installation Methods 0.000 description 5
- 230000001351 cycling effect Effects 0.000 description 4
- 238000010586 diagram Methods 0.000 description 3
- 239000008399 tap water Substances 0.000 description 3
- 235000020679 tap water Nutrition 0.000 description 3
- 230000008901 benefit Effects 0.000 description 2
- 230000001419 dependent effect Effects 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- 230000001934 delay Effects 0.000 description 1
- 230000003111 delayed effect Effects 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23N—REGULATING OR CONTROLLING COMBUSTION
- F23N1/00—Regulating fuel supply
- F23N1/08—Regulating fuel supply conjointly with another medium, e.g. boiler water
- F23N1/082—Regulating fuel supply conjointly with another medium, e.g. boiler water using electronic means
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24D—DOMESTIC- OR SPACE-HEATING SYSTEMS, e.g. CENTRAL HEATING SYSTEMS; DOMESTIC HOT-WATER SUPPLY SYSTEMS; ELEMENTS OR COMPONENTS THEREFOR
- F24D19/00—Details
- F24D19/10—Arrangement or mounting of control or safety devices
- F24D19/1006—Arrangement or mounting of control or safety devices for water heating systems
- F24D19/1009—Arrangement or mounting of control or safety devices for water heating systems for central heating
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/10—Control of fluid heaters characterised by the purpose of the control
- F24H15/144—Measuring or calculating energy consumption
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/10—Control of fluid heaters characterised by the purpose of the control
- F24H15/156—Reducing the quantity of energy consumed; Increasing efficiency
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/20—Control of fluid heaters characterised by control inputs
- F24H15/212—Temperature of the water
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/20—Control of fluid heaters characterised by control inputs
- F24H15/212—Temperature of the water
- F24H15/219—Temperature of the water after heating
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/20—Control of fluid heaters characterised by control inputs
- F24H15/242—Pressure
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/30—Control of fluid heaters characterised by control outputs; characterised by the components to be controlled
- F24H15/355—Control of heat-generating means in heaters
- F24H15/36—Control of heat-generating means in heaters of burners
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/40—Control of fluid heaters characterised by the type of controllers
- F24H15/414—Control of fluid heaters characterised by the type of controllers using electronic processing, e.g. computer-based
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23N—REGULATING OR CONTROLLING COMBUSTION
- F23N2225/00—Measuring
- F23N2225/08—Measuring temperature
- F23N2225/19—Measuring temperature outlet temperature water heat-exchanger
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23N—REGULATING OR CONTROLLING COMBUSTION
- F23N2225/00—Measuring
- F23N2225/22—Measuring heat losses
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23N—REGULATING OR CONTROLLING COMBUSTION
- F23N2227/00—Ignition or checking
- F23N2227/10—Sequential burner running
Definitions
- the present invention relates to a method and apparatus for improving heating system efficiency, particularly in heating systems which utilize a boiler to heat a fluid such as water or steam for transfer of heat via a heat exchanger to a space to be heated.
- Heating systems utilizing burners and boilers are at their least efficient when starting up. Prior to achieving operating temperature, the burner burns less cleanly. Heating systems generally operate at their peak efficiency when they are fully loaded. But heating systems generally are sized for the area to be heated in such a fashion that the only time the boiler is properly matched to the heating load is when the outside temperature is the value for which the system was designed for. A system is usually sized for the worst case temperature conditions as expected in a given geographic area. The net effect of this is that whenever the outside temperature exceeds this design temperature, the boiler is oversized for the heating load and is thus less efficient. Evidence of this is the cycling on and off of the burner which heats the boiler.
- Boilers have, as part of their inherent design, a heating media which is transferred throughout the heating load as a means of transferring the heat and subsequently heating the area. This heating media has a mass which retains heat even after the boiler shuts down.
- Various schemes have been used to take advantage of this thermal inertia to prolong off times and run times under certain load conditions.
- the present invention seeks to reduce the number of cycles without measuring ambient temperatures or measuring or relying on past off times to calculate delays.
- the invention is a microprocessor controlled device which, when properly connected to a gas or oil fueled hot water or steam boiler will render the effect of more fuel efficiency (because of less total burner on time) which correlates directly to fuel, energy and money savings.
- An added side benefit of the invention is the reduced electrical usage as well as reduced maintenance costs due to fewer burn cycles and less total "on" time of the boiler's burner.
- the invention intercepts and interrupts the signal sent by the boiler's built-in thermostat, which activates the burner.
- the boiler's built-in thermostat is never overridden by the invention, it is simply interrupted.
- the boiler thermostat is still responsible for the maximum temperature setting of the boiler.
- the invention determines the optimum instance of allowing the electrical path to be completed and subsequent starting of the boiler's burner, by taking a temperature reading (by invention sensors located as close as possible to the discharge of the boiler and/or domestic hot water heating coil) at the instant of a "call for heat" by the boiler thermostat, and storing these readings in the invention. These stored readings are compared to those of subsequent temperature readings via the same sensor(s).
- the temperature sensors also perform the task of monitoring the heating media temperature and or domestic water temperatures and will override the "temperature differential" determination (and complete the burner circuit) when a user adjustable absolute minimum value is reached.
- the temperature sensor(s) may be replaced or run in parallel with a pressure dependent switch or thermostat or any other means by which the sensor signal leads are electrically shorted when the desired minimum temperature is reached.
- the number of sensors is determined by the particular installation and depends on the application. (i.e. Heating only, Heating and Domestic hot water generation, or Domestic Hot Water generation only.)
- the invention intercepts and interrupts the signal sent by the boiler's built-in pressuretroll and/or domestic hot water thermostat which activates the burner.
- the boiler's built-in pressuretroll/thermostat is never overridden by the invention, it is simply interrupted.
- the boiler pressuretroll is still responsible for the maximum pressure setting of the boiler and domestic hot water thermostat the maximum water temperature.
- the invention determines the optimum instance of allowing the electrical path to be completed and subsequent starting of the boiler's burner, by taking a pressure/temperature reading (by invention sensors located as close as possible to the discharge of the boiler and/or domestic hot water heating coil) at the instant of a "call for heat" by either the boiler pressuretroll or hot water thermostat, and storing these readings in the invention.
- the invention sensors also perform the task of monitoring the heating media pressure and or domestic water temperature and will override the "pressure/temperature differential" determination (and complete the burner circuit) when a user adjustable absolute minimum value is reached.
- the pressure/temperature sensor(s) may be replaced or run in parallel with a pressure dependent switch, thermostat, pressuretroll or any other means by which the sensor signal leads are electrically shorted when the desired minimum pressure is reached.
- the number of sensors is determined by the particular installation and depends on the application. (i.e. Heating only, Heating and Domestic.
- a heating system is designed to heat a space 4.
- the system includes a boiler 6.
- Boiler 6 is fired by burner 8 for heating the boiler.
- the term boiler is conventionally used, whether or not the boiler actually boils water as in steam heat, or merely heats water as in forced hot water heating.
- Fluid heat transfer medium 16 such as water or steam
- heat exchanger such as radiator 18.
- Heart exchanger or radiator 18 is usually located remote from the boiler in space 4. Radiator 18 transfers heat to space 4.
- Domestic hot tap water is created by passing cold water from the domestic water supply 19A through coil 19B which absorbs heat from fluid heat transfer medium 16 and outflows through domestic hot water outflow pipe 19C, when demanded, as by hot water tap 19D.
- radiator 18 In a forced hot water heating system the cooled water from radiator 18 returns via return pipe 22 and is pumped by circulator pump 24 back to boiler 6.
- Energy value sensor 26 is a thermostat in a forced hot water system or is a pressuretrol in a steam system. Energy value sensor 26 is within boiler 6 and senses a low energy, either temperature or steam pressure, at which boiler 6 requires more heat.
- the senor 26 would switch on electrical power from power supply 27 which would supply and fire burner 8 to ignite the oil or gas and air mixture that burns and heats boiler 6 at said low energy until the sensor 26 senses a maximum energy, and terminates firing at or above the maximum energy,
- control circuit 28 is interposed between sensor 26 and burner 8 along wires 30 and 34. Control circuit 28 accomplishes the following steps:
- outflow energy sensor means 38 should be a sensor capable of sending a signal usable by an electronic circuit.
- the energy value is temperature.
- temperature transducers such as a thermocouple, but the applicant presently prefers a thermistor mounted at the boiler outflow.
- said thermistor has an inherent non-linearity, with greater voltage drops at lower temperatures, which non-linearity serves as means for a control program to respond linearly to thermistor voltage while having non-linear and increased sensitivity to smaller temperature decreases at lower temperatures.
- control program can logically induce non-linearity, making the system quicker to fire in response to lower energy drops at lower temperatures.
- the outflow energy sensor means 38 is a pressure sensor.
- Outflow energy sensor 38 senses an energy value of the outflow line 20 at boiler 6.
- Outflow energy sensor 39 senses an energy value of the domestic hot water outflow line 19C at boiler 6.
- Control circuit 28 continuously, or at frequent intervals, monitors the outflow energy values at sensors 38 and 39 .
- Control circuit 28 records the outflow energy values at a first time of the firing signal. When either sensor 38 or 39 communicates a sufficient voltage drop, below the value at the first time of the firing signal, to control circuit 28, circuit 28 allows the burner to fire. In installations where the boiler does not supply domestic hot water, domestic hot water outflow sensor 39 will not be provided or sensed or monitored by the control circuit.
- Fig. 4 illustrates an outflow energy value over time without using the present invention 40, and illustrates an outflow energy value over time using the present invention 42.
- boiler temperature causes thermostat 26 ( Fig. 1 ) to turn off burner 8 at 355 K (180°F) and turn on burner 8 at 305 K (170°F).
- thermostat 26 Fig. 1
- the boiler has just shut off and curve 44 decays slowly because the water remains still inside the boiler.
- T1 room temperature 45 has fallen to a lower limit 293 K (68°F) and space thermostat 50 Fig. 1 ) calls for circulator pump 24 by supplying power to it via wire 52. Cool water from heat exchanger 18 is forced by pump 24 into boiler 6.
- the water temperature in boiler 6 begins to drop as shown 44 between T1 and T2 in Fig.4 .
- the boiler thermostat detects 350 K (170°F) and fires the burner which terminates quickly at T3 when the boiler again reaches 355 K (180°F).
- T6 enough hot water has been forced out of the boiler 6 ( Fig.1 ) by circulator pump 24 and through radiator 18 to heat space 4 to thermostat 50's upper limit 295 K (72°F) in fig 4 .
- Thermostat 50 stops the circulator pump 24 which reduces boiler load and cycling between T6 ( Fig.4 ) and T7. But notice how many boiler cycles 60 occur between T2 and T6. Each of these cycles has a start-up period of inefficient burning and greater air pollution.
- control circuit 28 interrupts the power supply from boiler thermostat 26 to burner 8, and serves as means for preventing the boiler energy value sensor from firing the boiler, including a break 47 in a power supply wire 48 between: energy value sensor 26 within boiler 6, and the burner 8; and means 74 for switchably bridging said break.
- switch means for actuation by a voltage on the hot wire which switch means is an electronic circuit capable of a wide range of voltage inputs, preferably optoisolator circuit 70.
- the wide range of voltage inputs is between 24 VAC and 240 VAC, which copes with any heating system power supply known to the inventor throughout the world.
- Circuit 28 monitors outflow temperature 42 and records the outflow temperature at T2 when the optoisolator detects the boiler call. Circuit 28 continues to monitor outflow temperature.
- circuit 28 detects a change of a predetermined outflow energy value, ie. A temperature drop 42 ( fig 4 .) between T2 and T3 reflected by a voltage drop across thermistor 38, said change being an energy drop from the outflow energy value at the first time of the firing signal
- circuit 28 responds to the change by de-energizing relay 74 to its normally closed condition, and thereby supplying power to fire the burner. (Since relay 74 is normally closed, a failure in the invention will result in normal operation of heating system 2.)
- the burner Because the required change in outflow temperature caused the boiler temperature to fall to 344 K (160°F) the burner must remain on longer to reach its upper limit of 355 (180°F). This results in fewer burner cycles 80 ( fig. 4 ) between T2 and T6. By eliminating the waste of many start-ups, the invention achieves the same room temperature 45 with less burner time 80, greater efficiency, and less air pollution.
- the invention provides for a lowest limit to the energy outflow sensors, at which lowest limits a boiler thermostat call will result in immediate burner firing.
- the invention reacts to the present thermal load on the heating system.
- the invention adapts itself to load changes immediately. Therefore, it can be said that the invention serves as self adoptive means for reacting to immediate load changes to avoid reaching a boiler energy value low limit.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Computer Hardware Design (AREA)
- Control Of Steam Boilers And Waste-Gas Boilers (AREA)
- Control Of Combustion (AREA)
- Regulation And Control Of Combustion (AREA)
- Fluidized-Bed Combustion And Resonant Combustion (AREA)
- Heat-Pump Type And Storage Water Heaters (AREA)
- Steam Or Hot-Water Central Heating Systems (AREA)
Abstract
Description
- The present invention relates to a method and apparatus for improving heating system efficiency, particularly in heating systems which utilize a boiler to heat a fluid such as water or steam for transfer of heat via a heat exchanger to a space to be heated.
- Heating systems utilizing burners and boilers are at their least efficient when starting up. Prior to achieving operating temperature, the burner burns less cleanly. Heating systems generally operate at their peak efficiency when they are fully loaded. But heating systems generally are sized for the area to be heated in such a fashion that the only time the boiler is properly matched to the heating load is when the outside temperature is the value for which the system was designed for. A system is usually sized for the worst case temperature conditions as expected in a given geographic area. The net effect of this is that whenever the outside temperature exceeds this design temperature, the boiler is oversized for the heating load and is thus less efficient. Evidence of this is the cycling on and off of the burner which heats the boiler.
- Boilers have, as part of their inherent design, a heating media which is transferred throughout the heating load as a means of transferring the heat and subsequently heating the area. This heating media has a mass which retains heat even after the boiler shuts down. Various schemes have been used to take advantage of this thermal inertia to prolong off times and run times under certain load conditions.
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US Patent 2,266,245, issued 12/16/1941 to Osterheld for an OFF-PEAK WATER HEATING SYSTEM. It refers to: - " time and water temperature controlled means to cause energization of the heater at the start of the off-peak period in case less than a predetermined fractional part of the water content of a tank is hot at the start of an off-peak period , to delay energization of the heater for an adjustably predetermined length of time after start of an off-peak period in case said predetermined fractional part of the water content is hot at the start of an off-peak period."
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US Patent 4,108,375 issued Aug. 22, 1978 to Keeney for a CONTROL DEVICE AND PROCESS FOR HEATING AN INSTALLATION and refers to comparing "the heating medium temperature and the temperature outside the installation" and lowering the "heating medium to the lowest temperature required." -
US Patent 4,381,075 issued April 26, 1983 to Cargill et al. And refers to a MICROPROCESSOR BASED CONTROLLER FOR HEATING SYSTEM for: - "Modulating heat exchanger temperature as a function of outdoor temperature and, providing an override period for domestic hot water production."
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US for a BOILER CYCLING CONTROLLER which refers to "reducing the tendency to cycle" by reducing boiler flow temperature "as the outside temperature rises". There is a sensor:Patent 4, 637, 349 issued Jan. 20, 1987 to Robinson - "to override the control system and switch-on the boilers to ensure that the temperature at which return water enters the boilers does not drop below a predetermined value."
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US Patent 4,850, 310 issued Jul. 25 1989 to Wildgen for a BOILER CONTROL HAVING REDUCED NUMBER OF BOILER SEQUENCES FOR A GIVEN LOAD and purports: - "To reduce the number of boiler sequences over time the call signal applied to the boiler to initiate a sequence in response to a demand for heating is delayed as a function of outside temperature and time elapsed since the end of the previous heating cycle."
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US Patent 5,470,019 issued Nov. 28, 1995 to Martensson for a DEVICE FOR CONTROLLING HEATING BOILERS which purports to "measure the time between exceeding of the second temperature level and underpassing of the first level" and "to delay the start of the heating means" on the next cycle, after a boiler thermostat call, for a time interval which is a function of the measured time. The patent refers also to detecting tap water temperature and stopping the delay below a predetermined tap water temperature. - The present invention seeks to reduce the number of cycles without measuring ambient temperatures or measuring or relying on past off times to calculate delays.
- It is an object of the present invention to measure present load and prevent burner firing until the present load justifies firing the burner. It is an object to utilize the thermal mass of the heating media, which retains heat even after the boiler shuts down. The utilization of this retained heat in conjunction with more efficient burn cycles by the invention is what causes the fuel savings of the present invention.
- The invention is a microprocessor controlled device which, when properly connected to a gas or oil fueled hot water or steam boiler will render the effect of more fuel efficiency (because of less total burner on time) which correlates directly to fuel, energy and money savings. An added side benefit of the invention is the reduced electrical usage as well as reduced maintenance costs due to fewer burn cycles and less total "on" time of the boiler's burner.
- Experimentation has shown that by extending the "off" time of the burner even after called to start will result in a longer "on" time per "on" cycle but the total number of "on" cycles is reduced. By example if a burner was cycling "off" for 60 minutes and then "on" for 12 minutes this would result in a total number of "runs" of 10 and a total "on" time of 120 minutes in a 12 hour period. If we then employed the invention device, the "off" cycle time might change to 80 minutes with an "on" time of 14 minutes. This when extended out to a 12 hour period would yield a total number of run cycles of 7.7 with a total "on" time of 107.8 minutes. This is an 11.2% reduction in actual fuel and electrical consumption associated with the burner and also a 23% reduction in the number of burner "on" cycles.
- For Hot Water Boiler applications the invention intercepts and interrupts the signal sent by the boiler's built-in thermostat, which activates the burner. For safety reasons the boiler's built-in thermostat is never overridden by the invention, it is simply interrupted. The boiler thermostat is still responsible for the maximum temperature setting of the boiler. The invention determines the optimum instance of allowing the electrical path to be completed and subsequent starting of the boiler's burner, by taking a temperature reading (by invention sensors located as close as possible to the discharge of the boiler and/or domestic hot water heating coil) at the instant of a "call for heat" by the boiler thermostat, and storing these readings in the invention. These stored readings are compared to those of subsequent temperature readings via the same sensor(s). When the desired amount of difference (user adjustable) between either of the temperature readings, as compared to its corresponding stored value, is surpassed the electrical circuit will be completed. The temperature sensors also perform the task of monitoring the heating media temperature and or domestic water temperatures and will override the "temperature differential" determination (and complete the burner circuit) when a user adjustable absolute minimum value is reached. For system flexibility the temperature sensor(s) may be replaced or run in parallel with a pressure dependent switch or thermostat or any other means by which the sensor signal leads are electrically shorted when the desired minimum temperature is reached. The number of sensors is determined by the particular installation and depends on the application. (i.e. Heating only, Heating and Domestic hot water generation, or Domestic Hot Water generation only.)
- For Steam Boiler applications the invention intercepts and interrupts the signal sent by the boiler's built-in pressuretroll and/or domestic hot water thermostat which activates the burner. For safety reasons the boiler's built-in pressuretroll/thermostat is never overridden by the invention, it is simply interrupted. The boiler pressuretroll is still responsible for the maximum pressure setting of the boiler and domestic hot water thermostat the maximum water temperature. The invention determines the optimum instance of allowing the electrical path to be completed and subsequent starting of the boiler's burner, by taking a pressure/temperature reading (by invention sensors located as close as possible to the discharge of the boiler and/or domestic hot water heating coil) at the instant of a "call for heat" by either the boiler pressuretroll or hot water thermostat, and storing these readings in the invention. These stored readings are compared to those of subsequent pressure/temperature readings via the same sensor(s). When the desired amount of difference (user adjustable) between either of the pressure or temperature readings, as compared to its corresponding stored value, is surpassed the electrical circuit will be completed. The invention sensors also perform the task of monitoring the heating media pressure and or domestic water temperature and will override the "pressure/temperature differential" determination (and complete the burner circuit) when a user adjustable absolute minimum value is reached. For system flexibility the pressure/temperature sensor(s) may be replaced or run in parallel with a pressure dependent switch, thermostat, pressuretroll or any other means by which the sensor signal leads are electrically shorted when the desired minimum pressure is reached. The number of sensors is determined by the particular installation and depends on the application. (i.e. Heating only, Heating and Domestic.
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Fig. 1 is a system diagram showing the invention installed in a heating system. -
Fig. 2 is a circuit diagram showing the invention installed in a boiler burner circuit. -
Fig. 3 is a circuit diagram of the control circuit of the invention. -
Fig. 4 is a set of graphs correlating various system temperatures, without and with the invention operating. - As shown in
Fig.1 , a heating system, generally designated 2, is designed to heat aspace 4. The system includes aboiler 6.Boiler 6 is fired byburner 8 for heating the boiler. The term boiler is conventionally used, whether or not the boiler actually boils water as in steam heat, or merely heats water as in forced hot water heating. -
Flame 10 fromburner 8 heats theinternal walls 14, or heat exchange tubes not shown , ofboiler 6, which contains fluidheat transfer medium 16 such as water or steam, which delivers heat through anoutflow line 20 communicating fluidheat transfer medium 16 to heat exchanger, such asradiator 18. Heart exchanger orradiator 18 is usually located remote from the boiler inspace 4.Radiator 18 transfers heat tospace 4. - Domestic hot tap water is created by passing cold water from the
domestic water supply 19A throughcoil 19B which absorbs heat from fluidheat transfer medium 16 and outflows through domestic hotwater outflow pipe 19C, when demanded, as byhot water tap 19D. - In a forced hot water heating system the cooled water from
radiator 18 returns viareturn pipe 22 and is pumped bycirculator pump 24 back toboiler 6. - In a steam system the steam pressure within the boiler drives the steam through the
outflow pipe 20 toradiator 18, where it re-cools to water and drains back viareturn pipe 22 toboiler 6. - Some steam systems have no return pipe. The cooled water returns by draining back down
outflow pipe 20. -
Energy value sensor 26 is a thermostat in a forced hot water system or is a pressuretrol in a steam system.Energy value sensor 26 is withinboiler 6 and senses a low energy, either temperature or steam pressure, at whichboiler 6 requires more heat. - Conventionally the
sensor 26 would switch on electrical power frompower supply 27 which would supply andfire burner 8 to ignite the oil or gas and air mixture that burns and heatsboiler 6 at said low energy until thesensor 26 senses a maximum energy, and terminates firing at or above the maximum energy, - In the present invention, however, a
control circuit 28 is interposed betweensensor 26 andburner 8 alongwires Control circuit 28 accomplishes the following steps: - sensing a firing signal on
wire 30 from the boilerenergy value sensor 26; and - preventing the boiler
energy value sensor 26 from firingburner 8 by interrupting the power.Control circuit 28 opens the circuit fromsensor 26, switching the power toburner 8 off. - Meanwhile, on
outflow pipe 20, and located at the outflow of the boiler, is means 38 for sensing an energy value of the outflow at the boiler. This outflow energy sensor means 38 should be a sensor capable of sending a signal usable by an electronic circuit. In a hot water system, the energy value is temperature. There are various usable temperature transducers such as a thermocouple, but the applicant presently prefers a thermistor mounted at the boiler outflow. By using a negative energy value coefficient thermistor, said thermistor has an inherent non-linearity, with greater voltage drops at lower temperatures, which non-linearity serves as means for a control program to respond linearly to thermistor voltage while having non-linear and increased sensitivity to smaller temperature decreases at lower temperatures. - If a linear energy sensor is used, the control program can logically induce non-linearity, making the system quicker to fire in response to lower energy drops at lower temperatures.
- In a steam system, the outflow energy sensor means 38 is a pressure sensor.
-
Outflow energy sensor 38 senses an energy value of theoutflow line 20 atboiler 6.Outflow energy sensor 39 senses an energy value of the domestic hotwater outflow line 19C atboiler 6.Control circuit 28 continuously, or at frequent intervals, monitors the outflow energy values atsensors Control circuit 28 records the outflow energy values at a first time of the firing signal. When eithersensor circuit 28,circuit 28 allows the burner to fire. In installations where the boiler does not supply domestic hot water, domestic hotwater outflow sensor 39 will not be provided or sensed or monitored by the control circuit. -
Fig. 4 illustrates an outflow energy value over time without using the present invention 40, and illustrates an outflow energy value over time using thepresent invention 42. Without the invention boiler temperature causes thermostat 26 (Fig. 1 ) to turn offburner 8 at 355 K (180°F) and turn onburner 8 at 305 K (170°F). Infig. 4 at time T0 the boiler has just shut off andcurve 44 decays slowly because the water remains still inside the boiler. AtT1 room temperature 45 has fallen to alower limit 293 K (68°F) andspace thermostat 50Fig. 1 ) calls forcirculator pump 24 by supplying power to it viawire 52. Cool water fromheat exchanger 18 is forced bypump 24 intoboiler 6. The water temperature inboiler 6 begins to drop as shown 44 between T1 and T2 inFig.4 . At T2 the boiler thermostat detects 350 K (170°F) and fires the burner which terminates quickly at T3 when the boiler again reaches 355 K (180°F). By T6 enough hot water has been forced out of the boiler 6 (Fig.1 ) bycirculator pump 24 and throughradiator 18 to heatspace 4 tothermostat 50'supper limit 295 K (72°F) infig 4 .Thermostat 50 stops thecirculator pump 24 which reduces boiler load and cycling between T6 (Fig.4 ) and T7. But notice howmany boiler cycles 60 occur between T2 and T6. Each of these cycles has a start-up period of inefficient burning and greater air pollution. - Contrast now the performance graphs WITH INVENTION in
Fig.4 . AtT1 room temperature 45 causes room thermostat 50 (Fig. 1 ) to call for water circulation, pump 24 pumpinghot water 16 fromboiler 6outflow pipe 20past thermistor 38 which reads outflow temperature 42 (Fig.4 ) as a voltage. The hot outflow causesoutflow temperature 42 to rise towards boiler temperature between T1 and T2. Eventually cool water from radiator 18 (fig. 1 ) reentersboiler 6 and boiler temperature 62 (fig. 4 ) drops to 350K (170°F) at T2. - As shown in
Fig. 2 control circuit 28 interrupts the power supply fromboiler thermostat 26 toburner 8, and serves as means for preventing the boiler energy value sensor from firing the boiler, including abreak 47 in apower supply wire 48 between:
energy value sensor 26 withinboiler 6, and
theburner 8; and
means 74 for switchably bridging said break. - But voltage on
hot wire 30 is sensed inFig. 3 by switch means for actuation by a voltage on the hot wire, which switch means is an electronic circuit capable of a wide range of voltage inputs, preferablyoptoisolator circuit 70. The wide range of voltage inputs is between 24 VAC and 240 VAC, which copes with any heating system power supply known to the inventor throughout the world. -
Circuit 28monitors outflow temperature 42 and records the outflow temperature at T2 when the optoisolator detects the boiler call.Circuit 28 continues to monitor outflow temperature. Whencircuit 28 detects a change of a predetermined outflow energy value, ie. A temperature drop 42 (fig 4 .) between T2 and T3 reflected by a voltage drop acrossthermistor 38, said change being an energy drop from the outflow energy value at the first time of the firing signal,circuit 28 responds to the change by de-energizingrelay 74 to its normally closed condition, and thereby supplying power to fire the burner. (Sincerelay 74 is normally closed, a failure in the invention will result in normal operation ofheating system 2.) - Because the required change in outflow temperature caused the boiler temperature to fall to 344 K (160°F) the burner must remain on longer to reach its upper limit of 355 (180°F). This results in fewer burner cycles 80 (
fig. 4 ) between T2 and T6. By eliminating the waste of many start-ups, the invention achieves thesame room temperature 45 withless burner time 80, greater efficiency, and less air pollution. - When the system has been shut off long enough to allow the boiler or hot water coil to reach ambient temperature, the outflow energy value will not drop from the initial value at the burner firing signal. The burner would never fire. Thus, to enable an initial start-up, the invention provides for a lowest limit to the energy outflow sensors, at which lowest limits a boiler thermostat call will result in immediate burner firing.
- It can be seen that, by reacting to the outflow energy drop, the invention reacts to the present thermal load on the heating system. The invention adapts itself to load changes immediately. Therefore, it can be said that the invention serves as self adoptive means for reacting to immediate load changes to avoid reaching a boiler energy value low limit.
Claims (24)
- A method of operating a heating system (2) having:a boiler (6),a burner (8) for heating the boiler (6),a heat exchanger (18) remote from the boiler (6) for transferring heat to a space to be heated,a fluid heat transfer medium (16) for delivery of heat from the boiler (6) to the heat exchanger (18),an outflow line (20) communicating the fluid heat transfer medium (16) to said heat exchanger (18), andan energy value sensor (26) within the boiler (6) for:sensing a low energy value at which the boiler (6) requires more heat,firing said burner (8) at said low energy value,sensing a maximum energy value, andterminating firing above the maximum energy value, said method comprising:sensing a firing signal from the boiler energy value sensor (26); andpreventing the boiler energy value sensor (26) from firing the burner (8); characterised by:sensing an energy value of the outflow line at the boiler (6);monitoring the outflow energy value;recording the outflow energy value at a first time of the firing signal; then detecting a change of a predetermined outflow energy value, said change being an energy drop from the outflow energy value at the first time of the firing signal; andresponding to the change by firing the burner (8).
- A method according to claim 1 in which the energy value is a temperature and the energy value sensor (26) is a temperature sensor.
- A method according to claim 1 in which the energy value is a steam pressure and the energy value sensor (26) is a pressure sensor.
- A heating system having:a boiler (6),a burner (8),a heat exchanger (18), remote from the boiler (6), for transferring heat to a space to be heated,a fluid heat transfer medium (16) for delivery of heat to the heat exchanger (18),an outflow line (20) communicating the fluid heat transfer medium (16) to said heat exchanger (18), andan energy value sensor (26) within the boiler (6) for:sensing a low energy value at which the boiler (6) requires more heat,firing said burner (8) at said low energy value,sensing a maximum energy value, andterminating firing above the maximum energy value;means (28) for sensing a firing signal from the boiler energy value sensors (26);means (28) for preventing the boiler energy value sensor (26) from firing the burner (8);characterised by:means (38) for sensing an energy value of the outflow at the boiler;means (28) for recording the outflow energy value at a first time of the firing signal;means (28) for monitoring the outflow energy value;means (28) for detecting a change of a predetermined outflow energy value, said change being an energy decrease; andmeans (28) for responding to the change by firing the burner (8).
- An apparatus according to claim 4 in which the energy value is a temperature and the energy value sensor (26) is a temperature sensor.
- An apparatus according to claim 4 in which the energy value is a steam pressure and the energy value sensor (26) is a pressure sensor.
- Apparatus according to claim 4 in which the means (28) for preventing the boiler energy value sensor (26) from firing the boiler (6) comprises:a break in a power supply wire between:the energy value sensor (26) within the boiler, andthe burner (8); andmeans for switchably bridging said break.
- Apparatus according to claim 7 in which the means (28) for sensing a firing signal from the boiler energy value sensor comprises:a hot wire (30) switched on by the boiler energy value sensor in response to the low energy at which the boiler requires more heat; andswitch means (70) for actuation by a voltage on the hot wire.
- Apparatus according to claim 8 in which the switch means for actuation by a voltage on the hot wire is an electronic circuit (28) capable of a wide range of voltage inputs.
- Apparatus according to claim 9 in which the wide range of voltage inputs is between 24 VAC and 240 VAC.
- Apparatus according to claim 10 in which the hot wire electronic circuit comprises an optoisolator (70).
- Apparatus according to claim 4 in which the means for sensing an energy value of the outflow at the boiler (6) is an energy value sensor means for generating a signal usable by an electronic circuit, and said outflow energy value sensor means (38) is located at the outflow of the boiler (6).
- Apparatus according to claim 4 in which the means for recording the outflow energy value at a first time of the firing signal is an electronic circuit (28) which responds to the switch means by recording a voltage at the outflow energy value sensor means;
said electronic circuit (28) also serving as the means for monitoring the outflow energy value by monitoring a changing voltage at the outflow energy value sensor means;
said electronic circuit (28) also serving as the means for detecting the change of the outflow temperature by responding to a predetermined change in the changing voltage at the outflow sensor, corresponding to the change of the outflow temperature, by said electronic circuit actuating the switchably bridging means, thereby providing power to the burner and firing the burner. - Apparatus according to claim 13 in which:the energy value is temperature, andthe means for sensing the energy value of the outflow at the boiler (6) is a thermistor (38) mounted at the boiler outflow.
- Apparatus according to claim 13 in which the electronic circuit (28) comprises a microprocessor.
- Apparatus according to claim 4 in which the burner (8) cycles on and off when operated at less than maximum load, and serves as means for reducing a number of burner cycles in a given time period.
- Apparatus according to claim 16 which provides a means for reducing a number of start-ups and thereby serves as means for reducing air pollution.
- Apparatus according to claim 16 which provides a means for increasing burner run time per cycle, thereby resulting in improved fuel utilization.
- Apparatus according to claim 15 in which the microprocessor (28) is controlled by a program and the program has its own sensor calibration routine.
- Apparatus according to claim 19 wherein the program and sensor are calibrated to increase sensitivity and decrease the change of the predetermined outflow energy value decrease required to fire the burner at lower boiler energy values.
- Apparatus according to claim 20 wherein the outflow sensor is a negative energy value coefficient thermistor, said thermistor having an inherent non-linearity, with greater voltage drops at lower temperatures, which non-linearity serves as means for the program to respond linearly to thermistor voltage while having non-linear and increased sensitivity to smaller temperature decreases at lower temperatures.
- Apparatus according to claim 4 having means for immediately actuating the burner when the boiler energy value approaches ambient temperature, by sensing a lowest limit to the energy outflow sensor, at which lowest limit a boiler thermostat call will cause the control circuit to immediately fire the burner.
- Apparatus according to claim 4 wherein the program comprises self adaptive means for reacting to present thermal load changes to avoid reaching the boiler low energy value.
- Apparatus according to claim 21 having:means for immediately actuating the burner when the boiler energy value approaches ambient temperature, by sensing a lowest limit to the energy outflow sensor, at which lowest limit a boiler thermostat call will cause the control circuit to immediately fire the burner; andwherein the apparatus serves as self adaptive means for reacting to present thermal load changes to avoid reaching the boiler low energy value.
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/US1998/005625 WO1999048713A1 (en) | 1998-03-20 | 1998-03-20 | Method and apparatus for regulating heater cycles to improve fuel efficiency |
Publications (3)
Publication Number | Publication Date |
---|---|
EP1077821A1 EP1077821A1 (en) | 2001-02-28 |
EP1077821A4 EP1077821A4 (en) | 2009-06-24 |
EP1077821B1 true EP1077821B1 (en) | 2012-01-04 |
Family
ID=22266654
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP98913036A Expired - Lifetime EP1077821B1 (en) | 1998-03-20 | 1998-03-20 | Method and apparatus for regulating heater cycles to improve fuel efficiency |
Country Status (8)
Country | Link |
---|---|
EP (1) | EP1077821B1 (en) |
CN (1) | CN1104590C (en) |
AT (1) | ATE540267T1 (en) |
AU (1) | AU742376B2 (en) |
CA (1) | CA2324462C (en) |
HK (1) | HK1037160A1 (en) |
NZ (1) | NZ507617A (en) |
WO (1) | WO1999048713A1 (en) |
Families Citing this family (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
NL1032598C2 (en) * | 2006-09-29 | 2009-02-25 | Kamstrup B V | Device, system and method for controlling a heating system. |
NL1035645C2 (en) * | 2008-07-01 | 2010-01-05 | Agpo Bv | Burner controlling method for boiler in heating system, involves measuring pressure of transferred fluid, comparing measured pressure value with reference pressure value, and controlling burner of boiler based on results of comparison |
DE102008047070A1 (en) * | 2008-09-11 | 2010-03-25 | Viessmann Werke Gmbh & Co Kg | Method of operating a burner-equipped boiler |
GB2514554B (en) * | 2013-05-28 | 2016-06-01 | Dynamic Energy Products Ltd | Boiler control system and method |
GB2579662A (en) * | 2018-12-11 | 2020-07-01 | Domestic Energy Products Ltd | Boiler control system and method |
GB2589824B (en) * | 2019-09-27 | 2021-12-15 | Domestic Energy Products Ltd | Boiler Control System and Method |
Family Cites Families (10)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2266245A (en) | 1940-10-12 | 1941-12-16 | Mcgraw Electric Co | Off-peak water heating system |
US4108375A (en) | 1977-05-13 | 1978-08-22 | Energy Conservation Devices, Inc. | Control device and process for heating an installation |
US4381075A (en) | 1981-12-17 | 1983-04-26 | Thermonic Corp. | Microprocessor based controller for heating system |
US4844335A (en) * | 1982-03-10 | 1989-07-04 | Surgeonics Limited | Microprocessor controlled heating system |
GB8318452D0 (en) | 1983-07-07 | 1983-08-10 | Esg Controls Ltd | Boiler cycling controller |
US4850310A (en) * | 1986-06-30 | 1989-07-25 | Harry Wildgen | Boiler control having reduced number of boiler sequences for a given load |
GB8811186D0 (en) * | 1988-05-11 | 1988-06-15 | Hogan A P | Heating system control |
FR2661697B1 (en) * | 1990-05-02 | 1992-08-21 | Vape Sa Ets | DEVICE FOR FIXING A RAILWAY RAIL ON A CROSSING. |
US5125572A (en) * | 1991-04-26 | 1992-06-30 | General Electric Engineering, Inc. | Hot water heating control system |
EP0651873B1 (en) | 1992-07-16 | 1997-11-26 | Eurocorporation Ltd. | Device for controlling heating boilers |
-
1998
- 1998-03-20 WO PCT/US1998/005625 patent/WO1999048713A1/en active IP Right Grant
- 1998-03-20 AU AU67684/98A patent/AU742376B2/en not_active Ceased
- 1998-03-20 EP EP98913036A patent/EP1077821B1/en not_active Expired - Lifetime
- 1998-03-20 CN CN98813982A patent/CN1104590C/en not_active Expired - Fee Related
- 1998-03-20 NZ NZ507617A patent/NZ507617A/en not_active IP Right Cessation
- 1998-03-20 AT AT98913036T patent/ATE540267T1/en active
- 1998-03-20 CA CA002324462A patent/CA2324462C/en not_active Expired - Lifetime
-
2001
- 2001-08-28 HK HK01106093.2A patent/HK1037160A1/en not_active IP Right Cessation
Also Published As
Publication number | Publication date |
---|---|
WO1999048713A1 (en) | 1999-09-30 |
CN1294556A (en) | 2001-05-09 |
AU6768498A (en) | 1999-10-18 |
CA2324462C (en) | 2007-06-12 |
AU742376B2 (en) | 2002-01-03 |
CA2324462A1 (en) | 1999-09-30 |
ATE540267T1 (en) | 2012-01-15 |
HK1037160A1 (en) | 2002-02-01 |
NZ507617A (en) | 2003-03-28 |
CN1104590C (en) | 2003-04-02 |
EP1077821A4 (en) | 2009-06-24 |
EP1077821A1 (en) | 2001-02-28 |
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