EP3596391B1 - Method for controlling a combustion-gas operated heating device - Google Patents
Method for controlling a combustion-gas operated heating device Download PDFInfo
- Publication number
- EP3596391B1 EP3596391B1 EP18758556.7A EP18758556A EP3596391B1 EP 3596391 B1 EP3596391 B1 EP 3596391B1 EP 18758556 A EP18758556 A EP 18758556A EP 3596391 B1 EP3596391 B1 EP 3596391B1
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- Prior art keywords
- ionization
- gas
- air
- volume flow
- mixture
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- 238000000034 method Methods 0.000 title claims description 43
- 238000010438 heat treatment Methods 0.000 title claims description 9
- 239000000567 combustion gas Substances 0.000 title 1
- 239000000203 mixture Substances 0.000 claims description 49
- 238000005259 measurement Methods 0.000 claims description 45
- 230000001105 regulatory effect Effects 0.000 claims description 14
- 239000000446 fuel Substances 0.000 claims description 11
- 230000033228 biological regulation Effects 0.000 claims description 6
- 230000004913 activation Effects 0.000 claims description 5
- 238000001514 detection method Methods 0.000 claims description 5
- 239000003570 air Substances 0.000 description 81
- 239000007789 gas Substances 0.000 description 76
- 238000002485 combustion reaction Methods 0.000 description 10
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 8
- 239000003345 natural gas Substances 0.000 description 4
- 238000011161 development Methods 0.000 description 3
- 230000018109 developmental process Effects 0.000 description 3
- GVGLGOZIDCSQPN-PVHGPHFFSA-N Heroin Chemical compound O([C@H]1[C@H](C=C[C@H]23)OC(C)=O)C4=C5[C@@]12CCN(C)[C@@H]3CC5=CC=C4OC(C)=O GVGLGOZIDCSQPN-PVHGPHFFSA-N 0.000 description 2
- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 2
- 230000006978 adaptation Effects 0.000 description 2
- 239000012080 ambient air Substances 0.000 description 2
- 230000001419 dependent effect Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000006870 function Effects 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 238000000691 measurement method Methods 0.000 description 2
- 230000003213 activating effect Effects 0.000 description 1
- 230000009109 downstream regulation Effects 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 230000010355 oscillation Effects 0.000 description 1
- 239000001294 propane 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
- F23N1/02—Regulating fuel supply conjointly with air supply
- F23N1/022—Regulating fuel supply conjointly with air supply using electronic means
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23N—REGULATING OR CONTROLLING COMBUSTION
- F23N5/00—Systems for controlling combustion
- F23N5/02—Systems for controlling combustion using devices responsive to thermal changes or to thermal expansion of a medium
- F23N5/12—Systems for controlling combustion using devices responsive to thermal changes or to thermal expansion of a medium using ionisation-sensitive elements, i.e. flame rods
- F23N5/123—Systems for controlling combustion using devices responsive to thermal changes or to thermal expansion of a medium using ionisation-sensitive elements, i.e. flame rods using electronic means
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23L—SUPPLYING AIR OR NON-COMBUSTIBLE LIQUIDS OR GASES TO COMBUSTION APPARATUS IN GENERAL ; VALVES OR DAMPERS SPECIALLY ADAPTED FOR CONTROLLING AIR SUPPLY OR DRAUGHT IN COMBUSTION APPARATUS; INDUCING DRAUGHT IN COMBUSTION APPARATUS; TOPS FOR CHIMNEYS OR VENTILATING SHAFTS; TERMINALS FOR FLUES
- F23L5/00—Blast-producing apparatus before the fire
- F23L5/02—Arrangements of fans or blowers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23N—REGULATING OR CONTROLLING COMBUSTION
- F23N2223/00—Signal processing; Details thereof
- F23N2223/06—Sampling
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23N—REGULATING OR CONTROLLING COMBUSTION
- F23N2227/00—Ignition or checking
- F23N2227/20—Calibrating devices
Definitions
- the invention relates to a method for regulating a fuel gas-operated heater.
- Another problem with the control method is that different types of gas, e.g. Natural gas or liquid gas, as well as gas qualities, are used.
- the parameters of the control process must be adapted to the type of gas or gas quality, as otherwise the combustion will be unclean.
- the air ratio is preferably different for different burner power points and for different gas families (eg natural gas or liquid gas). This relationship is usually stored in the control unit in the form of performance-dependent ⁇ characteristics. Automatic gas type detection is required to automatically select the correct characteristic.
- the calorific value of the different gases corresponds approximately to the value of the air requirement L. This relationship is used to precontrol the modulating combustion air fan to a desired burner output. Since all gases change their volume under different temperatures and pressures, the conditions listed above only apply under the same pressure and temperature conditions. In the case of the different conditions for gas and air in practice, however, either the respective mass flow or correspondingly corrected volume flows must be used as a basis for regulating the combustion process (exa temperature increase of 30 K, air expands by 10% without more air molecules participating in the combustion process so that without correction the air ratio would decrease by 10%).
- the invention is based on the object of providing a gas type-independent method for regulating a fuel gas-operated heating device.
- the method should be able to determine the type of gas and its control parameters to be adaptable to the specific type of gas in further developments.
- a method for regulating a fuel gas-operated heater using an ionization setpoint power characteristic wherein a gas volume flow supplied via a gas supply and an air volume flow supplied via a fan are mixed to form a gas-air mixture and with an air ratio ⁇ based on a desired burner output Burner of the heater are fed.
- the air ratio ⁇ is monitored by means of an ionization measurement method of a burner flame of the burner.
- the mixture calibration is carried out by an ionization current control, in which the air ratio ⁇ of the gas-air mixture is adjusted to a value ⁇ ion-max at which a maximum ionization measurement signal is achieved on an ionization electrode of the ionization measurement in the burner flame. From the maximum ionization measurement signal, an ionization signal target value for the air ratio ⁇ is calculated at a calibration point and then the air ratio ⁇ ion-max is adjusted to a target air ratio ⁇ soll until the ionization measurement signal corresponds to the calculated ionization signal target value.
- the burner output is regulated for the respective heat demand on the heater.
- the amount of air required for this is changed by a control unit with the speed-controlled fan.
- the fan speed essentially corresponds to the air volume flow.
- the supplied gas volume flow is varied by an electrically modulated gas actuator or gas valve and measured by a gas mass flow sensor.
- the gas volume flow is also regulated via the control unit.
- the fan is preferably designed as a premix fan for mixing gas and air, so that the fan supplies a mixture volume flow to the burner.
- the gas-air mixture control is based on the continuous detection of the air volume flow by a fan speed detection and the downstream regulation of the gas volume via the control unit, the target value of the gas volume being taken from a stored characteristic curve.
- the plausibility check can determine whether the parameters influencing optimal combustion such as gas type, gas quality, exhaust system, components of the heater such as the non-return valves in front of the burner or the heat exchanger function in the desired way. Any change in these parameters affects the gas / air ratio and therefore the ionization measurement signal. This in turn can be detected.
- the parameters influencing optimal combustion such as gas type, gas quality, exhaust system, components of the heater such as the non-return valves in front of the burner or the heat exchanger function in the desired way. Any change in these parameters affects the gas / air ratio and therefore the ionization measurement signal. This in turn can be detected.
- the mixture calibration according to the invention enables the air ratio ⁇ to be adjusted and the heater to be converted into optimal combustion, taking into account the parameters influencing the combustion.
- the values of the air requirement value L are known for each gas, as described above.
- the gas type determination can thus be recorded automatically via the mixture calibration and stored in the control unit of the heater.
- the control device can then use laboratory-technically predefined control characteristics for the corresponding type of gas, in particular the corresponding ionization setpoint power characteristic, for further control.
- an advantageous embodiment of the method provides for the ionization setpoint power characteristic to be adapted by the mixture calibration over an entire power range of the heater if the ionization measurement signal is above a specified threshold value from an ionization measurement signal. Setpoint deviates. The adaptation of the ionization setpoint power characteristic takes place over its entire course by the ratio detected at the calibration point of the mixture calibration. The new ionization setpoint power characteristic is then saved. After the mixture calibration, the gas and air quantities are regulated along the stored characteristic curve with the corresponding performance-dependent air ratio and the newly determined air requirement value L.
- the air ratio ⁇ is adjusted by changing the gas volume flow or gas mass flow until the ionization measurement signal corresponds to the calculated ionization signal setpoint. This is possible in a simple and very precise way by activating the gas actuator. The actual gas mass flow can also be compared directly via the gas mass flow sensor.
- the mixture calibration can be run through in a long version and in a short version.
- a mixture volume flow is first generated at a defined fan speed and the associated air volume flow is recorded.
- a maximum value of the ionization signal is determined immediately, and from this a new ionization target value for a known one is determined and adjusted.
- the air requirement is determined from the gas and air volume regulated at this operating point and used for further mixture control.
- the associated ionization signal setpoint is determined via the ionization setpoint power characteristic.
- the ionization current signal is measured by the control unit and compared with the currently stored characteristic curve value.
- the steps of the ionization current regulation are then run through and the ionization target value power characteristic curve is adapted and stored as described above. In this case, the ionization signal maximum only has to be determined in exceptional cases.
- the mixture calibration is preferably carried out at a power point of the heater which corresponds to its maximum power or the burner power in a range of 50-70%.
- the method includes a transit time measurement to check the correct function of the gas mass sensor.
- a transit time measurement an amount of the supplied gas volume flow is actively varied via a control of the gas actuator or gas valve and the transit time between the control and the detection of the gas volume variation at the gas mass sensor is compared with a predefined setpoint transit time.
- the gas valve position can be increased or reduced by a pulse, an oscillation or an actual value jump when it is varied.
- the nominal run time is determined in advance in the laboratory. If the running time is above a limit value, there is a gas sensor fault and the heater is set to emergency mode, for example with limited modulation.
- the method also includes a run time measurement to determine the gas-air mixture volume flow.
- the amount of the supplied gas volume flow is actively varied and the transit time between the activation and a change in the ionization measurement signal and, optionally, additionally the level and type of change in the ionization measurement signal is recorded.
- the measured transit time is then with compared to a laboratory-based predetermined transit time-volume flow characteristic. If the effect on the ionization measurement signal due to the change in gas volume flow is too small or if the ionization measurement signal changes in the wrong direction, the heater is switched to emergency mode. If the effect is within the tolerance range, the mixture volume flow is determined from the comparison of the running time using a table of values determined by the laboratory.
- the transit time measurement is repeated at predetermined time intervals.
- a plausibility check of a sufficient air volume flow is continuously implemented over the entire performance range.
- the blower speed is checked for plausibility in terms of safety.
- the runtime measurement can be used as a further expansion stage in order to carry out a combustion air calculation according to the stationary recorded values at various power points. This means that the internally stored characteristic curve for calculating the combustion air can be corrected dynamically.
- the method also provides that the actual air volume flow is calculated from a difference between the set air volume flow and the mixture volume flow determined via the transit time measurement and optionally a measured temperature of the air volume flow.
- the method provides that the fan speed and a target air volume flow resulting therefrom are continuously compared with the actual air volume flow. If the speed deviates too much in the course of operation despite the same air volume flow, for example due to a blocked heat exchanger, the control unit switches off the heater and issues an alarm message.
- the method includes the integration of the mixture calibration in a starting method for cold starting the heater. Ignition attempts of the gas-air mixture are carried out until a burner flame is detected via the ionization measurement.
- the gas mass flow present at the time of ignition is kept constant and stored in the control unit.
- the starting air requirement L start is determined from the ratio of the gas volume flow to the air volume flow taken from the blower characteristic and corresponding to the ignition speed, and the gas type is determined from this as described above.
- the starting point for the next burner start is determined from the stored gas mass flow and the ignition range.
- FIG 1 is a schematic structure of a heater 100 for carrying out the control method with a modulating premix blower 5, the ambient air a and mixes with gas.
- the gas is fed to the premix blower 5 via a gas line in which a gas safety valve 1, a gas valve 2 controllable by way of example via a motor M and a gas mass sensor 3 are arranged.
- the gas inlet pressure d is adapted to the gas control pressure c.
- the mixture After mixing with ambient air, the mixture has the mixture pressure b.
- an optional non-return flap 6 is provided at the blower outlet.
- the mixture then has the burner pressure e. This is followed by the burner 28 with the ionization electrode 7 arranged in the burner flame and a siphon 10 connected to the burner housing.
- the heat exchanger 18 is arranged around the burner 28. Continued in the flow direction, the exhaust system follows with the exhaust flap 8. The exhaust gas pressure f prevails in the exhaust system. The amount of gas and the fan speed and therefore the air ratio are regulated by means of the control unit 9, in which the regulating characteristics are stored.
- FIG. 2 shows the partial process of the mixture calibration of the control procedure in the short version.
- the fan speed n of the premix fan 5 is set to a fixed value via the control device 9 and the actual air volume flow vL-ist is calculated in step 300 using the run time measurement described above.
- the ionization flow control takes place at a fixed air volume flow vL-act, in that the gas quantity is increased until a maximum ionization measurement signal (lo-max) is reached.
- the ionization signal setpoint (lo-soll, lo-neu) for the desired air ratio ⁇ is calculated from the maximum ionization measurement signal and the gas quantity is then regulated in step 615 until the ionization measurement signal corresponds to the calculated ionization signal setpoint lo-soll.
- the short version of the ionization calibration takes place with every mixture calibration.
- FIG. 3 shows the partial process of the mixture calibration of the control method in the long version.
- the fan speed n of the premix fan 5 is set to a fixed value via the control device 9 and the actual air volume flow vL-ist is calculated.
- the ionization signal setpoint value lo-soll is determined using the ionization setpoint power characteristic and the burner power P.
- the ionization current at the ionization electrode 7 is measured by the control unit 9 in an ionization measurement process and compared with the characteristic value. If the values match, the measured ionization current is used for further mixture calibration.
- the ionization setpoint performance characteristic is calibrated by increasing the gas quantity in step 612 with a fixed air volume flow vL-act until a maximum ionization measurement signal lo-max is reached. From the maximum ionization measurement signal, the ionization signal setpoint 624 (lo-soll) for the desired air ratio ⁇ (at 625) is calculated. According to step 613, the original ionization setpoint power characteristic curve lo-old is corrected over its entire power range by the ratio detected at the calibration point of the mixture calibration to the new ionization setpoint power characteristic curve lo-new. The new ionization target value performance characteristic lo-new is stored in the memory of the control device 9.
- step 615 the amount of gas is regulated until the ionization measurement signal corresponds to the calculated target ionization signal value lo-soll.
- ionization calibration is only carried out in exceptional cases.
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Combustion & Propulsion (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Regulation And Control Of Combustion (AREA)
Description
Die Erfindung betrifft ein Verfahren zur Regelung eines brenngasbetriebenen Heizgerätes.The invention relates to a method for regulating a fuel gas-operated heater.
Gattungsbildende Verfahren sind aus dem Stand der Technik bekannt, beispielsweise aus der Offenbarung gemäß der Druckschrift
Eine Problematik der Regelungsverfahren liegt zudem darin, dass für die Verbrennung unterschiedliche Gasarten, z.B. Erdgas oder Flüssiggas, sowie Gasqualitäten zum Einsatz kommen. Die Parameter des Regelungsverfahrens müssen auf die Gasart bzw. Gasqualität angepasst werden, da die Verbrennung andernfalls unsauber abläuft.Another problem with the control method is that different types of gas, e.g. Natural gas or liquid gas, as well as gas qualities, are used. The parameters of the control process must be adapted to the type of gas or gas quality, as otherwise the combustion will be unclean.
Für Regelungsverfahren der vorliegenden Art gilt, dass die Luftzahl λ in der Technik das Verhältnis zwischen Luft und Gas bestimmt, wobei beispielsweise eine Luftzahl λ=1,3 einem Luftüberschuss von 30% entspricht. Ein für ein bestimmtes Gas erforderlicher Luftbedarf L ist abhängig von der Gasbeschaffenheit, wobei beispielhafte Werte für Propan: L= ca. 30, Erdgas aus der Gruppe H: L= ca. 10 und Erdgas aus der Gruppe L: L= ca. 8 sind. Die Luftzahl ist in der Praxis vorzugsweise bei verschiedenen Brennerleistungspunkten und bei verschiedenen Gasfamilien (z.B. Erdgas oder Flüssiggas) unterschiedlich. In der Regel wird dieser Zusammenhang in Form von leistungsabhängigen λ-Kennlinien im Steuergerät abgespeichert. Zur automatischen Auswahl der richtigen Kennlinie ist eine automatische Gasarterkennung nötig. Der zu einem definierten Gas-Luftgemisch erforderliche Luftvolumenstrom vL berechnet sich aus dem Gasvolumenstrom vG multipliziert mit dem Luftbedarf L multipliziert mit der Luftzahl: vL= vG ∗ L ∗ A.For control methods of the present type, the air ratio λ in technology determines the ratio between air and gas, with an air ratio λ = 1.3 for example corresponding to an air excess of 30%. An air requirement L required for a certain gas depends on the gas quality, with exemplary values for propane: L = approx. 30, natural gas from group H: L = approx. 10 and natural gas from group L: L = approx. 8 . In practice, the air ratio is preferably different for different burner power points and for different gas families (eg natural gas or liquid gas). This relationship is usually stored in the control unit in the form of performance-dependent λ characteristics. Automatic gas type detection is required to automatically select the correct characteristic. The air volume flow vL required for a defined gas-air mixture is calculated from the gas volume flow vG multiplied by the air requirement L multiplied by the air ratio: vL = vG ∗ L ∗ A.
Der Brennwert der unterschiedlichen Gase entspricht näherungsweise dem Wert des Luftbedarfes L. Dieser Zusammenhang wird zur Vorsteuerung des modulierenden Verbrennungsluftgebläses auf eine gewünschte Brennerleistung genutzt. Da alle Gase unter unterschiedlichen Temperaturen und Drücken ihr Volumen verändern, gelten die oben aufgeführten Bedingungen nur bei gleichen Druck- und Temperaturbedingungen. Bei den in der Praxis jedoch abweichenden Bedingungen für Gas und Luft muss zur Regelung des Verbrennungsprozess entweder der jeweilige Massenstrom oder entsprechend korrigierte Volumenströme zugrunde gelegt werden (Beispiel: bei 30 K Temperaturerhöhung dehnt sich Luft um 10% aus, ohne dass mehr Luftmoleküle am Verbrennungsprozess beteiligt wären, so dass ohne Korrektur die Luftzahl um 10% sinken würde).The calorific value of the different gases corresponds approximately to the value of the air requirement L. This relationship is used to precontrol the modulating combustion air fan to a desired burner output. Since all gases change their volume under different temperatures and pressures, the conditions listed above only apply under the same pressure and temperature conditions. In the case of the different conditions for gas and air in practice, however, either the respective mass flow or correspondingly corrected volume flows must be used as a basis for regulating the combustion process (example: at a temperature increase of 30 K, air expands by 10% without more air molecules participating in the combustion process so that without correction the air ratio would decrease by 10%).
Der Erfindung liegt die Aufgabe zugrunde, ein gasartenunabhängiges Verfahren zur Regelung eines brenngasbetriebenen Heizgerätes bereitzustellen. Zudem soll in Weiterbildungen mit dem Verfahren die Gasart bestimmbar und seine Regelungsparameter an die bestimmte Gasart anpassbar sein.The invention is based on the object of providing a gas type-independent method for regulating a fuel gas-operated heating device. In addition, the method should be able to determine the type of gas and its control parameters to be adaptable to the specific type of gas in further developments.
Diese Aufgabe wird durch die Merkmalskombination gemäß Patentanspruch 1 gelöst.This object is achieved by the combination of features according to patent claim 1.
Erfindungsgemäß wird ein Verfahren zur Regelung eines brenngasbetriebenen Heizgerätes unter Nutzung einer lonisations-Sollwert-Leistungskennlinie vorgeschlagen, wobei ein über eine Gaszuführung gelieferter Gasvolumenstrom und ein über ein Gebläse gelieferter Luftvolumenstrom zu einem Gas-Luftgemisch gemischt und mit einer auf einer gewünschten Brennerleistung basierenden Luftzahl λ einem Brenner des Heizgerätes zugeführt werden. Die Luftzahl λ wird mittels einem lonisationsmessverfahren einer Brennerflamme des Brenners überwacht. Zudem wird eine Plausibilitätskontrolle durchgeführt, bei der ein lonisationsmesssignal des lonisationsmessverfahrens ausgewertet wird, und im Falle einer Abweichung von einem lonisationsmesssignal-Sollwert eine Gemischkalibration des Gas-Luftgemisches erfolgt. Die Gemischkalibration erfolgt durch eine lonisationsstromregelung, bei der die Luftzahl λ des Gas-Luftgemisches auf einen Wert λion-max angepasst wird, bei dem ein maximales lonisationsmesssignal an einer lonisationselektrode der lonisationsmessung in der Brennerflamme erreicht ist. Aus dem maximalen lonisationsmesssignal wird ein lonisationssignalsollwert für die Luftzahl λ in einem Kalibrierungspunkt errechnet und anschließend die Luftzahl λion-max auf eine Soll-Luftzahl λsoll angepasst, bis das lonisationsmesssignal dem errechneten lonisationssignalsollwert entspricht.According to the invention, a method for regulating a fuel gas-operated heater using an ionization setpoint power characteristic is proposed, wherein a gas volume flow supplied via a gas supply and an air volume flow supplied via a fan are mixed to form a gas-air mixture and with an air ratio λ based on a desired burner output Burner of the heater are fed. The air ratio λ is monitored by means of an ionization measurement method of a burner flame of the burner. There is also a plausibility check carried out, in which an ionization measurement signal of the ionization measurement method is evaluated, and in the event of a deviation from an ionization measurement signal target value, a mixture calibration of the gas-air mixture takes place. The mixture calibration is carried out by an ionization current control, in which the air ratio λ of the gas-air mixture is adjusted to a value λ ion-max at which a maximum ionization measurement signal is achieved on an ionization electrode of the ionization measurement in the burner flame. From the maximum ionization measurement signal, an ionization signal target value for the air ratio λ is calculated at a calibration point and then the air ratio λ ion-max is adjusted to a target air ratio λ soll until the ionization measurement signal corresponds to the calculated ionization signal target value.
Grundsätzlich erfolgt die Regelung der Brennerleistung der jeweiligen Wärmebedarfsanforderung an das Heizgerät. Die dazu erforderliche Luftmenge wird mit dem drehzahlgeregeltem Gebläse von einem Steuergerät verändert. Die Gebläsedrehzahl entspricht im Wesentlichen dem Luftvolumenstrom. Der zugeführte Gasvolumenstrom wird durch ein elektrisch moduliertes Gasstellglied bzw. Gasventil variiert und durch einen Gasmassenstromsensor gemessen. Die Regelung des Gasvolumenstroms erfolgt ebenfalls über das Steuergerät. Das Gebläse ist vorzugsweise als Vormischgebläse zur Mischung von Gas und Luft ausgebildet, so dass das Gebläse einen Gemischvolumenstrom an den Brenner liefert. Die Gas-Luftgemischregelung beruht auf der kontinuierlichen Erfassung des Luftvolumenstroms durch eine Gebläsedrehzahlerfassung und der nachgeschalteten Ausregelung der Gasmenge über das Steuergerät, wobei der Sollwert der Gasmenge aus einer gespeicherten Kennlinie entnommen wird.Basically, the burner output is regulated for the respective heat demand on the heater. The amount of air required for this is changed by a control unit with the speed-controlled fan. The fan speed essentially corresponds to the air volume flow. The supplied gas volume flow is varied by an electrically modulated gas actuator or gas valve and measured by a gas mass flow sensor. The gas volume flow is also regulated via the control unit. The fan is preferably designed as a premix fan for mixing gas and air, so that the fan supplies a mixture volume flow to the burner. The gas-air mixture control is based on the continuous detection of the air volume flow by a fan speed detection and the downstream regulation of the gas volume via the control unit, the target value of the gas volume being taken from a stored characteristic curve.
Über die Plausibilitätskontrolle kann mit dem erfindungsgemäßen Verfahren festgestellt werden, ob die eine optimale Verbrennung beeinflussenden Parameter wie Gasart, Gasqualität, Abgassystem, Baugruppen des Heizgerätes wie die Rückschlagklappen vor dem Brenner oder der Wärmetauscher in der gewünschten Art und Weise funktionieren. Jede Änderung dieser Parameter beeinflusst das Gas-Luftverhältnis und mithin das lonisationsmesssignal. Dies wiederum kann detektiert werden.Using the method according to the invention, the plausibility check can determine whether the parameters influencing optimal combustion such as gas type, gas quality, exhaust system, components of the heater such as the non-return valves in front of the burner or the heat exchanger function in the desired way. Any change in these parameters affects the gas / air ratio and therefore the ionization measurement signal. This in turn can be detected.
Die erfindungsgemäße Gemischkalibration ermöglicht die Anpassung der Luftzahl λ und die Überführung des Heizgeräts in die optimale Verbrennung unter Berücksichtigung der die Verbrennung beeinflussenden Parametern.The mixture calibration according to the invention enables the air ratio λ to be adjusted and the heater to be converted into optimal combustion, taking into account the parameters influencing the combustion.
Vorteilhafterweise kann mit dem Verfahren aus der Soll-Luftzahl λsoll ein Luftbedarfswert L errechnet und über den Luftbedarfswert L die Gasart bestimmt werden, denn aus der Formel vL= vG∗L∗λ folgt, dass L=vL/(vG∗λ). Die Werte des Luftbedarfswerts L sind wie oben beschrieben für jedes Gas bekannt. Die Gasartbestimmung kann somit automatisch über die Gemischkalibration erfasst und im Steuergerät des Heizgerätes hinterlegt werden. Zudem kann das Steuergerät anschließend labortechnisch vordefinierte Regelungskennlinien für die entsprechende Gasart, insbesondere die entsprechende lonisations-Sollwert-Leistungskennlinie, zur weiteren Regelung verwenden.Advantageously, the method can be used to calculate an air requirement value L from the target air ratio λ should and the gas type can be determined using the air requirement value L, because the formula vL = vG ∗ L ∗ λ implies that L = vL / (vG ∗ λ). The values of the air requirement value L are known for each gas, as described above. The gas type determination can thus be recorded automatically via the mixture calibration and stored in the control unit of the heater. In addition, the control device can then use laboratory-technically predefined control characteristics for the corresponding type of gas, in particular the corresponding ionization setpoint power characteristic, for further control.
Da die Regelung des Heizgerätes entlang der lonisations-Sollwert-Leistungskennlinie erfolgt, sieht eine vorteilhafte Ausführung des Verfahrens vor, die lonisations-Sollwert-Leistungskennlinie durch die Gemischkalibration über einen gesamten Leistungsbereich des Heizgerätes anzupassen, wenn das lonisationsmesssignal oberhalb eines festgelegten Schwellenwerts von einem lonisationsmesssignal-Sollwert abweicht. Die Anpassung der lonisations-Sollwert-Leistungskennlinie erfolgt dabei über ihren gesamten Verlauf um das bei dem Kalibrierungspunkt der Gemischkalibration erfasste Verhältnis. Die neue lonisations-Sollwert-Leistungskennlinie wird anschließend gespeichert. Nach der Gemischkalibration werden die Gas- und Luftmenge entlang der gespeicherten Kennlinie mit der entsprechend leistungsabhängigen Luftzahl und dem neu festgelegten Luftbedarfswert L geregelt.Since the control of the heater takes place along the ionization setpoint power characteristic, an advantageous embodiment of the method provides for the ionization setpoint power characteristic to be adapted by the mixture calibration over an entire power range of the heater if the ionization measurement signal is above a specified threshold value from an ionization measurement signal. Setpoint deviates. The adaptation of the ionization setpoint power characteristic takes place over its entire course by the ratio detected at the calibration point of the mixture calibration. The new ionization setpoint power characteristic is then saved. After the mixture calibration, the gas and air quantities are regulated along the stored characteristic curve with the corresponding performance-dependent air ratio and the newly determined air requirement value L.
Bei der lonisationsstromregelung der Gemischkalibration wird die Luftzahl λ durch Veränderung des Gasvolumenstromes oder Gasmassenstromes angepasst, bis das lonisationsmesssignal dem errechneten lonisationssignalsollwert entspricht. Dies ist über die Ansteuerung des Gasstellglieds auf einfach und sehr exakte Weise möglich. Über den Gasmassenstromsensor kann zudem unmittelbar der tatsächliche Gasmassenstrom abgeglichen werden.In the case of the ionization flow regulation of the mixture calibration, the air ratio λ is adjusted by changing the gas volume flow or gas mass flow until the ionization measurement signal corresponds to the calculated ionization signal setpoint. This is possible in a simple and very precise way by activating the gas actuator. The actual gas mass flow can also be compared directly via the gas mass flow sensor.
Die Gemischkalibration kann in einer Langversion und in einer Kurzversion durchlaufen werden. In beiden Varianten wird zunächst ein Gemischvolumenstrom bei einer festgelegten Gebläsedrehzahl erzeugt und der zugehörige Luftvolumenstrom erfasst. Bei der Kurzversion wird unmittelbar ein Maximalwert des lonisationssignales ermittelt und daraus ein neuer lonisations-sollwert für ein bekanntes ermittelt und eingeregelt. Aus der in diesem Arbeitspunkt eingeregelten Gas- und Luftmenge wird der Luftbedarf bestimmt und für die weitere Gemischregelung genutzt.The mixture calibration can be run through in a long version and in a short version. In both variants, a mixture volume flow is first generated at a defined fan speed and the associated air volume flow is recorded. In the short version, a maximum value of the ionization signal is determined immediately, and from this a new ionization target value for a known one is determined and adjusted. The air requirement is determined from the gas and air volume regulated at this operating point and used for further mixture control.
In der Langversion wird im Anschluss an die Erfassung des Luftvolumenstroms über die lonisations-Sollwert-Leistungskennlinie der zugehörige lonisationssignalsollwert ermittelt. Das lonisationsstromsignal wird vom Steuergerät gemessen und mit dem aktuell hinterlegten Kennlinienwert verglichen. Anschließend werden die Schritte der lonisationsstromregelung durchlaufen und die lonisations-Sollwert-Leistungskennlinie wie vorstehend beschrieben angepasst und gespeichert. In diesem Fall muss nur in Ausnahmefällen das lonisationssignalmaximum ermittelt werden.In the long version, following the acquisition of the air volume flow, the associated ionization signal setpoint is determined via the ionization setpoint power characteristic. The ionization current signal is measured by the control unit and compared with the currently stored characteristic curve value. The steps of the ionization current regulation are then run through and the ionization target value power characteristic curve is adapted and stored as described above. In this case, the ionization signal maximum only has to be determined in exceptional cases.
Die Gemischkalibration erfolgt vorzugsweise bei einem Leistungspunkt des Heizgerätes, der in einem Bereich von 50-70% seiner Maximalleistung bzw. der Brennerleistung entspricht.The mixture calibration is preferably carried out at a power point of the heater which corresponds to its maximum power or the burner power in a range of 50-70%.
Grundsätzlich wird bei dem vorliegenden Regelungsverfahren zur Festlegung des über das Gebläse gelieferten Luftvolumenstroms für die erforderliche bzw. angeforderte Brennerleistung aus einer Luftzahl-Leistungskennlinie die gewünschte Luftzahl ermittelt und daraus der über das Gebläse zu liefernde Luftvolumenstrom über die Formel vL=P∗λ berechnet.In the present control method to determine the air volume flow supplied by the fan for the required or requested burner output, the desired air ratio is determined from an air ratio performance characteristic and from this the air volume flow to be supplied by the fan is calculated using the formula vL = P ∗ λ.
In einer Weiterbildung des Verfahrens ist vorgesehen, dass es eine Laufzeitmessung zur Prüfung der richtigen Funktion des Gasmassensensors umfasst. Bei der Laufzeitmessung wird eine Menge des zugeführten Gasvolumenstroms über eine Ansteuerung des Gasstellglieds bzw. Gasventils aktiv variiert und die Laufzeit zwischen der Ansteuerung und der Erfassung der Gasvolumenvariation an dem Gasmassensensor mit einem vordefinierten Laufzeit-Sollwert verglichen. Die Gasventilstellung kann bei der Variation um einen Impuls, eine Schwingung oder einen Istwertsprung erhöht oder reduziert werden. Der Laufzeit-Sollwert wird vorab labortechnisch ermittelt. Liegt die Laufzeit oberhalb eines Grenzwertes, liegt eine Gassensorstörung vor und das Heizgerät wird in einen Notbetrieb, beispielsweise mit beschränkter Modulation gesetzt.In a further development of the method it is provided that it includes a transit time measurement to check the correct function of the gas mass sensor. In the transit time measurement, an amount of the supplied gas volume flow is actively varied via a control of the gas actuator or gas valve and the transit time between the control and the detection of the gas volume variation at the gas mass sensor is compared with a predefined setpoint transit time. The gas valve position can be increased or reduced by a pulse, an oscillation or an actual value jump when it is varied. The nominal run time is determined in advance in the laboratory. If the running time is above a limit value, there is a gas sensor fault and the heater is set to emergency mode, for example with limited modulation.
Zudem umfasst das Verfahren in einer Ausführungsvariante eine Laufzeitmessung zur Bestimmung des Gas-Luft-Gemischvolumenstromes. Dabei wird die Menge des zugeführten Gasvolumenstroms aktiv variiert und die Laufzeit zwischen der Ansteuerung und einer Änderung des lonisationsmesssignals und optional zusätzlich der Höhe und Art der Änderung des lonisationsmesssignals erfasst. Die gemessene Laufzeit wird anschließend mit einer labortechnisch vorbestimmten Laufzeit-Volumenstrom-Kennlinie verglichen. Ist die Auswirkung auf das lonisationsmesssignal aufgrund der Gasvolumenstromänderung zu gering oder verändert sich das lonisationsmesssignal in die falsche Richtung, wird das Heizgerät in den Notbetrieb gefahren. Liegt die Auswirkung im Toleranzbereich, wird aus dem Laufzeitvergleich über eine labortechnisch ermittelte Wertetabelle der Gemischvolumenstrom bestimmt.In one embodiment variant, the method also includes a run time measurement to determine the gas-air mixture volume flow. The amount of the supplied gas volume flow is actively varied and the transit time between the activation and a change in the ionization measurement signal and, optionally, additionally the level and type of change in the ionization measurement signal is recorded. The measured transit time is then with compared to a laboratory-based predetermined transit time-volume flow characteristic. If the effect on the ionization measurement signal due to the change in gas volume flow is too small or if the ionization measurement signal changes in the wrong direction, the heater is switched to emergency mode. If the effect is within the tolerance range, the mixture volume flow is determined from the comparison of the running time using a table of values determined by the laboratory.
Zudem ist vorteilhaft, dass die Laufzeitmessung in vorbestimmten Zeitabständen wiederholt wird. Dadurch wird stetig über den gesamten Leistungsbereich eine Plausibilisierung eines hinreichenden Luftvolumenstromes umgesetzt. Somit wird die Gebläsedrehzahl sicherheitstechnisch plausibilisiert. Als weitere Ausbaustufe kann die Laufzeitmessung herangezogen werden, um eine Verbrennungsluftberechnung gemäß den stationär erfassten Werten an verschiedenen Leistungspunkten durchzuführen. Dadurch kann die intern gespeicherte Kennlinie zur Verbrennungsluftberechnung dynamisch korrigiert werden.It is also advantageous that the transit time measurement is repeated at predetermined time intervals. As a result, a plausibility check of a sufficient air volume flow is continuously implemented over the entire performance range. In this way, the blower speed is checked for plausibility in terms of safety. The runtime measurement can be used as a further expansion stage in order to carry out a combustion air calculation according to the stationary recorded values at various power points. This means that the internally stored characteristic curve for calculating the combustion air can be corrected dynamically.
Das Verfahren sieht ferner vor, dass der tatsächliche Luftvolumenstrom aus einer Differenz des eingestellten Luftvolumenstroms und dem über die Laufzeitmessung bestimmten Gemischvolumenstroms und optional einer gemessene Temperatur des Luftvolumenstroms berechnet wird.The method also provides that the actual air volume flow is calculated from a difference between the set air volume flow and the mixture volume flow determined via the transit time measurement and optionally a measured temperature of the air volume flow.
Als weiteres Merkmal sieht das Verfahren vor, dass die Gebläsedrehzahl und ein sich draus ergebender Soll-Luftvolumenstrom kontinuierlich mit dem tatsächlichen Luftvolumenstrom abgeglichen werden. Bei einer zu großen Abweichung der Drehzahl im Laufe des Betriebs trotz gleichen Luftvolumenstromes, beispielsweise durch einen verstopften Wärmetauscher, schaltet das Steuergerät das Heizgerät ab und gibt eine Alarmmeldung aus.As a further feature, the method provides that the fan speed and a target air volume flow resulting therefrom are continuously compared with the actual air volume flow. If the speed deviates too much in the course of operation despite the same air volume flow, for example due to a blocked heat exchanger, the control unit switches off the heater and issues an alarm message.
Als weiterer Aspekt umfasst das Verfahren die Integration der Gemischkalibration in ein Startverfahren zum Kaltstart des Heizgerätes. Dabei werden Zündversuche des Gas-Luftgemisches durchgeführt, bis über die lonisationsmessung eine Brennerflamme detektiert wird. Der zum Zündzeitpunkt vorliegende Gasmassenstrom wird konstant gehalten und im Steuergerät abgespeichert. Aus dem Verhältnis aus Gasvolumenstrom zu dem aus der Gebläsekennlie entnommenen und der Zünd-Drehzahl entsprechenden Luftvolumenstrom wird der Start-Luftbedarf Lstart ermittelt und daraus wie vorstehend beschrieben die Gasart bestimmt. Aus dem abgespeicherten Gasmassenstrom und dem Zündbereich wird der Startpunkt für den nächsten Brennerstart festgelegt.As a further aspect, the method includes the integration of the mixture calibration in a starting method for cold starting the heater. Ignition attempts of the gas-air mixture are carried out until a burner flame is detected via the ionization measurement. The gas mass flow present at the time of ignition is kept constant and stored in the control unit. The starting air requirement L start is determined from the ratio of the gas volume flow to the air volume flow taken from the blower characteristic and corresponding to the ignition speed, and the gas type is determined from this as described above. The starting point for the next burner start is determined from the stored gas mass flow and the ignition range.
Soweit vorliegend auf "Volumenstrom" abgestellt wird, kann in gleicher Weise auch der Massenstrom angewendet werden.If the focus is on "volume flow", the mass flow can also be used in the same way.
Andere vorteilhafte Weiterbildungen der Erfindung sind in den Unteransprüchen gekennzeichnet bzw. werden nachstehend zusammen mit der Beschreibung der bevorzugten Ausführung der Erfindung anhand der Figuren näher dargestellt. Es zeigen:
- Fig. 1
- einen schematischen Aufbau eines Heizgerätes;
- Fig. 2
- einen Ablauf der Gemischkalibration in der Kurzversion,
- Fig. 3
- einen Ablauf der Gemischkalibration in der Langversion.
- Fig. 1
- a schematic structure of a heater;
- Fig. 2
- a sequence of the mixture calibration in the short version,
- Fig. 3
- a sequence of mixture calibration in the long version.
In
Claims (13)
- A method for regulating a fuel-gas-operated heating device (100) using an ionization target value-output characteristic curve, wherein the regulation of the heating device (100) takes place along the ionization target value-output characteristic curve and in this casea. a gas volume flow supplied via a gas supply and an air volume flow supplied via a fan are mixed to form a gas-air mixture and are supplied to a burner (28) of the heating device with an air-fuel ratio λ based on a desired burner output,b. the air-fuel ratio A is monitored by means of an ionization measuring method of a burner flame of the burner (28),c. a plausibility check is performed in which an ionization measurement signal of the ionization measuring method is evaluated, and in the case of a deviation from an ionization measurement signal target value, a mixture calibration of the gas-air mixture takes place, and whereind. the mixture calibration is carried out by an ionization current regulation, in which the gas-air mixture is adapted to a value at which a maximum ionization measurement signal is achieved, and an ionization signal target value for the target air-fuel ratio λtarget at a calibration point is calculated from the maximum ionization measurement signal, wherein in the ionization current regulation, the mixture calibration of the air-fuel ratio A is adapted by changing the gas volume flow or gas mass flow until the ionization measurement signal corresponds to the calculated ionization signal target value.
- The method as claimed in claim 1, characterized in that an air requirement value L is calculated from the target air-fuel ratio λtargat and a gas type of the gas is determined via the air requirement value.
- The method as claimed in claim 1 or 2, characterized in that, in the mixture calibration, the air-fuel ratio A is adapted by changing the gas volume flow until the ionization measurement signal corresponds to the calculated ionization signal target value.
- The method as claimed in any one of the preceding claims, characterized in that the regulation of the heating device (100) takes place along the ionization target value-output characteristic curve and the ionization target value-characteristic curve is adapted by the mixture calibration over an entire output range of the heating device if the ionization measurement signal deviates from an ionization measurement signal target value above a defined threshold value.
- The method as claimed in any one of the preceding claims, characterized in that, in the mixture calibration, firstly a volume flow is produced and measured at a fixed fan speed, and the associated ionization signal target value is ascertained via the ionization target value-output characteristic curve.
- The method as claimed in any one of the preceding claims, characterized in that, to establish the air volume flow supplied via the fan for a required burner output, the desired air-fuel ratio is ascertained from an air-fuel ratio-output characteristic curve and the air volume flow to be supplied via the fan is calculated therefrom.
- The method as claimed in any one of the preceding claims, characterized in that it comprises a runtime measurement for checking a gas mass sensor, in which a quantity of the supplied gas volume flow is actively varied via an activation of a gas valve (2) and a runtime between the activation and a detection of the gas volume variation at the gas mass sensor (3) is compared to a predefined runtime target value.
- The method as claimed in any one of the preceding claims, characterized in that it comprises a runtime measurement for determining the gas-air mixture volume flow, in which a quantity of the supplied gas volume flow is actively varied via an activation of a gas valve (2) and a runtime between the activation and a change of the ionization measurement signal and optionally additionally a level and type of the change of the ionization measurement signal are detected, and wherein the measured runtime is compared to a runtime-volume flow characteristic curve predetermined in a laboratory and the mixture volume flow is determined therefrom.
- The method as claimed in any one of the preceding claims, characterized in that the actual volume flow is calculated from a difference of a set air value flow and the mixture volume flow determined via the runtime measurement and optionally a measured temperature of the air volume flow.
- The method as claimed in any one of preceding claims 8-9, characterized in that the runtime measurement is repeated at predetermined time intervals,
- The method as claimed in any one of preceding claims 9-10, characterized in that a fan speed of the fan (5) and a target air volume flow resulting therefrom are continuously compared to the actual air volume flow.
- The method as claimed in any one of the preceding claims, characterized in that the mixture calibration is performed at an output point of the heating device which corresponds to a range of 50-70% of its maximum output.
- The method as claimed in any one of the preceding claims, characterized in that the mixture calibration is integrated into a starting method for the cold start of the heating device.
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PCT/EP2018/071669 WO2019091612A1 (en) | 2017-11-08 | 2018-08-09 | Method for controlling a combustion-gas operated heating device |
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