EP4027058A1 - Method and device for detecting liquid in a fan of a heater - Google Patents

Abstract

The invention relates to a method for detecting the presence of liquid (15) in a fan (4) of a heater (1) which is operated with a mixture of air and fuel gas which is supplied to a burner (2) by the fan (4). at least one physical variable that is characteristic of the function of the blower (4) is measured at least once when a predeterminable time interval has elapsed from the start of the heater (1) and is compared with values based on experience and/or calibration data, and a deviation (d1, d2, d3) is evaluated by the empirical values and/or calibration data by a predeterminable value as an indication of liquid (15) in the blower (4). A corresponding arrangement has a control and regulation unit (5) for starting up the blower (4) by means of a pulse width modulated current and for processing a measured actual value of the speed (D) of the blower (4), with a comparator (12) in the control - and control unit (5) is present, which is set up to compare the speed (D) and/or the pulse width of the pulse-width-modulated current with stored empirical values and, if there is a deviation (d1, d2, d3) by a predeterminable size, a warning or to trigger an error message. The present invention allows the presence of liquid in the blower to be detected early and reliably in a heater without additional instrumentation, thereby preventing subsequent damage.

Description

The invention relates to a method and an arrangement for detecting the presence of liquid in a fan of a heater that is operated with a mixture of air and a fuel gas.

Modern heaters, especially so-called condensing boilers, are operated using premix burners, in which air is first mixed with an amount of fuel gas suitable for clean combustion and the resulting mixture is then fed to a burner by a blower. The burner distributes the mixture into a combustion chamber where it is burned to form flames. Any exhaust gases are discharged through an exhaust system. Combustion gases containing hydrogen or hydrocarbons also produce water vapor during combustion, which can form condensate at various points in the heater together with possible other components. A non-return valve, which is generally located in the exhaust system, prevents water vapor or condensate from entering the fan. This applies in particular to multi-occupancy systems where several heaters are connected to one chimney.

Nevertheless, it is necessary for high safety standards, or at least desirable, water, condensate or liquid in general in the fan of such a heater, z. B. as a result of a malfunction of the non-return valve because liquid in this and neighboring components can lead to corrosion damage and other malfunctions. So far, however, such a detection has not been provided for heaters. Such an increase in security is particularly desirable in the case of multi-occupancy systems.

If the heater is to be started, a control and regulation unit typically initiates all associated processes, including starting and increasing the speed of the fan up to a predefinable setpoint. To do this, the blower is supplied with one- to three-phase alternating current, the effective strength of which is specified by pulse width modulation (so-called PWM signal). The control and regulation unit receives current measured values for the speed of the fan from the fan, so that its speed can be regulated to the desired value.

The object of the present invention is to at least alleviate the problems explained with reference to the prior art, and in particular to detect the presence of liquid in the fan without additional instrumentation by means of the data and measured values that are available anyway can be used for this, e.g. B. to trigger a warning or error message or to initiate maintenance.

A method and an arrangement as well as a computer program product according to the independent claims serve to solve this task. Advantageous refinements and developments of the invention are specified in the respective dependent claims. The description, in particular in connection with the drawing, illustrates the invention and specifies further exemplary embodiments.

A method for detecting the presence of liquid in a fan of a heater contributes to this, the heater being operated with a mixture of air and fuel gas which is supplied to a burner by the fan. According to this, at least one physical variable that is characteristic of the function of the fan is measured at least once at the end of a specifiable time interval from the start of the heater and compared with (previously known, determined and/or stored) empirical values and/or calibration data, with a deviation from the empirical values and /or calibration data is evaluated by a predetermined size (or predetermined amount) as an indication of liquid in the fan. The (previously known, determined and/or stored) empirical values and/or calibration data include, in particular, values and/or curves of the characteristic physical variable under consideration, with (practically) no liquid and a (significant) amount of liquid being present in the blower, with possibly also a or there may be several limit values for certain amounts of liquid. The empirical values and/or calibration data can also be available as a map, e.g. B. depending on the operating status of the heater, the ambient conditions, the position of the fan, etc. Until now, it was not assumed that (small) amounts of liquid in the fan, i.e. typically at the bottom of a fan housing, would have an impact on its actual function, which is why it was not expected that the presence of liquid in the fan could be detected and distinguished from other effects based on measurement data of the fan function. However, precise measurements have shown that, surprisingly, this is indeed the case. Liquid in the housing has a characteristically different effect than other malfunctions or operational changes, as explained below using a few examples. In particular, it may also be possible to use one or more additional exclusion procedures (e.g. due to further evaluations of the same or at least one other/additional physical quantity) finally to unequivocally conclude that liquid is present in the blower.

A "physical variable" is understood here to mean any measurable property or variable or any operating parameter (derived from it) or any state variable (derived from it) that can say something about the state and/or the behavior of the blower, i.e. in particular variables such as speed, effective power consumption, mass flow, pressure difference, flow rate, temperature, noise level and the like. "Experience values" can be preset and/or stored in particular for the heater, e.g. as the result of long-term tests or long-term observations of the operation of such heaters. "Calibration data" can be set or determined, for example, when the heater is (first) set up; they may relate to levels that allow proper or efficient operation under site conditions. The “predeterminable size” of the deviation can include a fixedly predetermined value or a value that may be variably adapted to the operating conditions. It is possible that the detection of a deviation by at least the predefinable size (immediately) leads to a warning and/or safety action in the heating device or its control and regulation unit.

Investigations have shown that with liquid in the blower, startup is more difficult and e.g. B. the speed therefore increases more slowly than without liquid. Correspondingly, a larger pulse width of a pulse width modulated current driving the blower is required to run up over a longer period of time than without liquid. Other physical variables that are characteristic of the function of the blower also behave in a similar way. The invention makes use of this to (so far not systematically measured or recorded) presence of liquid in the fan at each start or at a desired proportion of the starts of the heater.

In a particularly simple embodiment of the invention, the physical variable is measured only once at a significant point in time after the start, e.g. B. 0.1 to 2 s [seconds] afterwards, preferably 0.3 to 1.5 s, (determined and) compared, for greater accuracy also more (measurements and) comparisons can be carried out at intervals from one another. If the deviation from calibration data or empirical values, e.g. B. at> 10% (example of a predetermined size), this can be interpreted systemically as an indication of liquid.

Particularly preferably (not just at a single point in time, but) the time profile of at least one physical variable that is characteristic of the function of the fan is measured and observed from the time the heater is started and compared with empirical values and/or calibration data, with deviations in the profile from the empirical values and/or calibration data are evaluated by a specifiable size as an indication of liquid in the blower. A continuous or quasi-continuous observation of the course over time increases the accuracy and helps to avoid misinterpretations.

The speed of the blower is particularly suitable as a physical quantity to be observed. This is measured in all modern heaters anyway, and the measured value is constantly available to the control and regulation unit, so that it can be used not only for known controls but also to determine the presence of liquid in the fan without additional instrumentation.

Another suitable physical variable is a pulse width of a pulse width modulated electrical current (usually an alternating current with 1 or 3 phases) delivered by the control and regulation unit to the blower after the heater has started. Put simply, pulse width modulation (PWM) means switching on and off quickly (e.g. with a frequency of 1 kHz [kilohertz] or more) in a changeable rhythm, with the ratio between switch-on times (pulse widths) and switch-off times changing (modulating) becomes. This ratio is also called duty cycle and can also be specified as a percentage. A 100% duty cycle means the power is on all the time, a 50% duty cycle means the power is on only half the time.

A warning or error message is preferably triggered when there is an indication of liquid in the blower. This can be signaled acoustically via a signaling device or optically via a display or an indicator device (e.g. warning light) or sent to an external location in order to trigger maintenance. In this way, it is possible to prevent liquid in the blower or adjacent components (e.g. fuel gas valve) from causing damage through corrosion or leading to undefined states of the heater.

According to another aspect, an arrangement for detecting the presence of liquid in a fan of a heater is proposed, wherein the heater is operated with a mixture of air and fuel gas, which is supplied to a burner by the fan. There is a control and regulation unit that is set up to control the start-up of the blower and its speed up to a target value by means of a pulse width modulated current and to process a measured actual value of the speed, with (at least) one comparator in the tax and Control unit is present, which is set up to compare the speed and / or the pulse width of the pulse width modulated current with stored calibration data and / or empirical values and to trigger a warning or error message if there is a deviation by a predetermined size. A control and regulation unit that is typical for such heaters already has data storage for calibration data and/or empirical values and at least one microprocessor, so that it can take on the additional functions described without great effort. The speed of the fan and the PWM signal for controlling the fan are also constantly available there.

The comparator is preferably set up to carry out a comparison not just at one point in time after the start, but rather at a number of points in time and/or quasi-continuously after the start of the heater. In this way, greater accuracy of data interpretation can be achieved, so that erroneous warning or fault messages (false alarms) cannot easily occur.

A further aspect relates to a computer program product comprising instructions which cause the arrangement described to carry out the method described. The comparison of measured data with empirical values or calibration data requires a program and data for the control and regulation unit of the heater, both of which have to be updated from time to time. Such a computer program product can contribute to this.

The explanations for the method can be used for a more detailed characterization of the arrangement, and vice versa. The arrangement can also be set up in such a way that the method is carried out with it.

Fig. 1:

schematisch ein typisches Heizgerät mit einer entsprechend ausgestalteten Steuer- und Regeleinheit und

Fig. 2:

ein Diagramm zur Veranschaulichung des Verhaltens von Drehzahl und PWM-Signal eines Gebläses mit und ohne Flüssigkeit beim Start eines Heizgerätes.

A schematic embodiment of the invention, to which it is not limited, and the mode of operation of the method will now be explained in more detail with reference to the drawing. They represent:

Figure 1:

schematically a typical heater with a correspondingly designed control and regulation unit and

Figure 2:

a diagram to illustrate the behavior of the speed and PWM signal of a fan with and without liquid when starting a heater.

1 1 schematically shows a typical heater 1 (e.g. a so-called condensing boiler) which can be operated with a mixture of air and fuel gas. A fan 4 draws in ambient air, which is mixed with a fuel gas quantity suitable for clean combustion via a fuel gas valve 6 . The mixture is supplied to a burner 2 by the blower 4 via a mixture channel 7 and burned in a combustion chamber 3 . Exhaust gases are discharged via an exhaust pipe 10 with a non-return valve 11 . A central control and regulation unit 5 controls and regulates the heater. This also includes activating the fan 4 via a signal line 8 with a pulse width modulated current (PWM signal) when starting the heater 1 and monitoring the speed D of the fan when starting and running up via a measuring line 9 in order to quickly reduce the speed D to a to bring predetermined setpoint and regulate there. It has been shown that, under such conditions, the presence of liquid 15 in the fan 4 (for example at the bottom of a fan housing) can also be determined without additional installations or instrumentation. For this purpose, the control and regulation unit 5 has a comparator 12 and at least one data memory 13 for calibration data and/or empirical values. After starting the heater 1 so the Compare the course of the speed D and/or the PWM signal as a function of the time after the start with stored or specified courses (calibration data). In this case, liquid 15 in the blower leads to very typical deviations (d1, d2, d3) which, above a predetermined size, e.g. B. more than 5%, preferably more than 10%, at any time of stored values can be interpreted as an indication of the presence of liquid 15. It can be sufficient to determine the deviation at just one suitable point in time, but more reliable results are obtained when comparing at two or more points in time, in particular when comparing values measured continuously or at short time intervals (quasi-continuously). If there are indications of the presence of liquid 15 in the blower, a signaling device 14 is then activated and/or a warning or error message is otherwise triggered, in particular also sent to a remote location in order, for example, to B. to trigger maintenance.

2 shows an example of the course of speed D and PWM signal within the first 2 s after starting heater 1. The time t is plotted on the x-axis, the speed D (revolutions per second) on the left and the right on the right Size of the PWM signal in percent. The solid line corresponds to the progression of the PWM signal without liquid 15 in fan 4. In order to achieve rapid acceleration of speed D (dotted line) of fan 4, a continuous current (duty cycle of 100%) is first sent for 0.5 s . With undisturbed operation, the PWM signal can then be lowered because the speed D has quickly approached its target value (constant speed in the diagram). This can be recognized by a drop in the previously constant PWM signal. If, on the other hand, there is liquid 15 in the blower 4, the course of the rotational speed D and the PWM signal is different. The dashed line shows the course of the PWM signal that then occurs, which only shows a drop from the constant signal much later. the Deviation d3, more than 0.4 s here, can therefore serve as an indication of liquid 15 in the blower 4. The speed D also behaves differently in the presence of liquid (dash-dotted line). It increases more slowly and reaches z. B. after 0.5 s only about 3500 instead of 5000, which can be determined by the comparator 12 as a deviation d1. Experiments even showed that the speed D increased beyond a set target value, which e.g. B. after about 1.4 s to a deviation d2 from the undisturbed curve upwards to over 7500 instead of 6000, before the target value (here 6000) slowly adjusted. It can be seen that liquid 15 in fan 4 can be determined very reliably by comparator 12 according to the invention.

The present invention allows the presence of liquid in the blower to be detected early and reliably in a heater without additional instrumentation, thereby preventing subsequent damage.

Reference List

1

heater

2

burner

3

combustion chamber

4

fan

5

control and regulation unit

6

fuel gas valve

7

mixture channel

8th

Signal line (PWM signal)

9

measuring line (speed)

10

exhaust pipe

11

check valve

12

comparator

13

data storage

14

signaling device

15

liquid

D

rotational speed

t

time

d1

first deviation (speed)

d2

second deviation (speed)

d3

third deviation (PWM signal)

Claims (8)

A method for detecting the presence of liquid (15) in a fan (4) of a heater (1) which is operated with a mixture of air and fuel gas which is fed from the fan (4) to a burner (2), at least a physical variable that is characteristic of the function of the blower (4) is measured at least once at the end of a specifiable time interval from the start of the heater (1) and compared with at least empirical values or calibration data, and with a deviation (d1, d2, d3) of at least the empirical values or calibration data is evaluated by a specifiable size as an indication of liquid (15) in the fan (4). Method according to Claim 1, in which the course over time of at least one physical variable which is characteristic of the function of the blower (4) is measured and observed from the start of the heating device (1) and compared with at least empirical values or calibration data, and in which deviations (d1, d2, d3) the progression of at least the empirical values or calibration data around a predeterminable variable is evaluated as an indication of liquid (15) in the blower (4). Method according to claim 1 or 2, wherein the physical quantity is the speed (D) of the fan. Method according to one of the preceding claims, wherein the physical variable is a pulse width of a control and regulation unit (5) to the blower (4). the start of the heater (1) delivered pulse width modulated electric current. Method according to one of the preceding claims, a warning or fault message being triggered if there is an indication of liquid (15) in the fan (4). Arrangement for detecting the presence of liquid (15) in a fan (4) of a heater (1), which is operated with a mixture of air and fuel gas, which is supplied by the fan (4) to a burner (2), wherein a There is a control and regulation unit (5) which is set up to control the start-up of the blower (4) and the increase in its speed (D) by means of a pulse-width-modulated current and to process a measured actual value of the speed (D), and wherein a comparator (12) is present in the control and regulation unit (5), which is set up to compare the speed (D) and/or the pulse width of the pulse-width-modulated current with stored calibration data and/or empirical values and, if there is a deviation (d1, d2, d3) in order to trigger a warning or fault message for a predetermined variable. Arrangement according to Claim 6, in which the comparator (12) is set up to carry out a comparison at least at a plurality of points in time or quasi-continuously after the start of the heating device (1). A computer program product comprising instructions which cause the arrangement according to any one of claims 6 to 7 to carry out the method according to any one of claims 1 to 5.

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