US20180306445A1 - Igniter failure detection assemblies for furnaces, and corresponding methods of detecting igniter failure - Google Patents
Igniter failure detection assemblies for furnaces, and corresponding methods of detecting igniter failure Download PDFInfo
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- US20180306445A1 US20180306445A1 US15/916,868 US201815916868A US2018306445A1 US 20180306445 A1 US20180306445 A1 US 20180306445A1 US 201815916868 A US201815916868 A US 201815916868A US 2018306445 A1 US2018306445 A1 US 2018306445A1
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- igniter
- hot surface
- relay
- surface igniter
- resistor
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- 238000001514 detection method Methods 0.000 title claims abstract description 46
- 238000000034 method Methods 0.000 title claims abstract description 21
- 230000000712 assembly Effects 0.000 title abstract description 7
- 238000000429 assembly Methods 0.000 title abstract description 7
- 239000000411 inducer Substances 0.000 claims description 18
- 238000002485 combustion reaction Methods 0.000 claims description 12
- 230000004044 response Effects 0.000 claims description 12
- 230000000977 initiatory effect Effects 0.000 claims description 5
- 230000003750 conditioning effect Effects 0.000 claims description 2
- 230000008859 change Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 230000008569 process Effects 0.000 description 2
- 230000008439 repair process Effects 0.000 description 2
- 230000008901 benefit Effects 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23Q—IGNITION; EXTINGUISHING-DEVICES
- F23Q23/00—Testing of ignition installations
- F23Q23/08—Testing of components
- F23Q23/10—Testing of components electrically
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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
- F23N5/26—Details
- F23N5/265—Details using electronic means
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23Q—IGNITION; EXTINGUISHING-DEVICES
- F23Q7/00—Incandescent ignition; Igniters using electrically-produced heat, e.g. lighters for cigarettes; Electrically-heated glowing plugs
- F23Q7/06—Incandescent ignition; Igniters using electrically-produced heat, e.g. lighters for cigarettes; Electrically-heated glowing plugs structurally associated with fluid-fuel burners
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- 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
- F24H15/104—Inspection; Diagnosis; Trial operation
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- 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
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- 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
- F24H9/00—Details
- F24H9/20—Arrangement or mounting of control or safety devices
- F24H9/2064—Arrangement or mounting of control or safety devices for air heaters
- F24H9/2085—Arrangement or mounting of control or safety devices for air heaters using fluid fuel
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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
- F23N2227/02—Starting or ignition cycles
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F23—COMBUSTION APPARATUS; COMBUSTION PROCESSES
- F23N—REGULATING OR CONTROLLING COMBUSTION
- F23N2231/00—Fail safe
- F23N2231/12—Fail safe for ignition failures
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- 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
- F24H15/407—Control of fluid heaters characterised by the type of controllers using electrical switching, e.g. TRIAC
Abstract
Exemplary embodiments are provided of igniter failure detection assemblies for furnaces. In an exemplary embodiment, an igniter failure detection assembly includes a hot surface igniter, an igniter relay coupled to the hot surface igniter, a resistor coupled in parallel with the hot surface igniter and defining a node between the igniter relay, the resistor and hot surface igniter, and a controller configured to detect a voltage at the node and determine whether a fault condition of the hot surface igniter exists based on the detected voltage at the node. A detected node voltage corresponding to a normal operation resistance value of the hot surface igniter is indicative of a normal operating hot surface igniter, and a detected node voltage corresponding to a resistance value of the resistor is indicative of a fault condition of the hot surface igniter. Example methods of detecting an igniter fault condition are also disclosed.
Description
- This application claims the benefit and priority of Indian Patent Application No. 201721014345 filed Apr. 22, 2017. The entire disclosure of the above application is incorporated herein by reference.
- The present disclosure generally relates to igniter failure detection assemblies for furnaces, and corresponding methods of detecting igniter failure.
- This section provides background information related to the present disclosure which is not necessarily prior art.
- Furnaces often include an igniter which heats up based on a supplied current to ignite a combustible gas of the furnace. Igniter relays are typically used to supply current to the igniter. Furnaces also typically include a flame sensor to detect the presence or absence of a flame.
- The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure.
-
FIG. 1 is a block diagram of an igniter failure detection assembly according to one exemplary embodiment of the present disclosure; -
FIG. 2 is a block diagram of an igniter failure detection assembly ofFIG. 1 , including a flame sensor; -
FIG. 3 is a circuit diagram of an igniter failure detection assembly according to another exemplary embodiment of the present disclosure; and -
FIG. 4 is a chart of example voltage conditions of the igniter failure detection assembly ofFIG. 3 . - Example embodiments will now be described more fully with reference to the accompanying drawings.
- As recognized herein, hot surface igniters (e.g., electric resistance igniters, etc.) in HVAC systems are often used to ignite combustible gas in a furnace of the HVAC system. The hot surface igniter is powered by a voltage supplied from a power source (e.g., a 110 VAC supply, etc.) via an electromechanical switch call relay (e.g., an igniter relay, etc.). During operation, the hot surface igniter could become damaged and fail to heat up (e.g., ignite, etc.) the combustible gas of the furnace. Separately, the igniter relay has a limited lifespan and the igniter relay could fail to open or close. Existing systems are not capable of detecting failures (e.g., fault conditions, etc.) of the hot surface igniter.
- As also recognized herein, adding a resistance (e.g., high value resistor, etc.) in parallel with the hot surface igniter allows for detection of fault conditions of the hot surface igniter. For example, when the hot surface igniter is working properly, the effective resistance of the parallel resistor and hot surface igniter will be low (e.g., will correspond to a resistance of the hot surface igniter, etc.). When the hot surface igniter is damaged (e.g., has a fault condition, etc.), the effective resistance of the parallel resistor and hot surface igniter would become high (e.g., correspond to a resistance value of the resistor, etc.). This change in resistance could be detected by a controller, etc., to separate detection of hot surface igniter faults and igniter relay faults.
- Exemplary embodiments are provided of igniter failure detection assemblies for a furnace.
FIG. 1 illustrates an exemplary embodiment of an igniterfailure detection assembly 100 having ahot surface igniter 102. Thehot surface igniter 102 is adapted to, in response to receiving a current, heat up to ignite a combustible gas of the furnace. - The
hot surface igniter 102 may include any suitable resistive igniter, etc., and is adapted to ignite the combustible gas of the furnace via heat when thehot surface igniter 102 is supplied with a current. For example, during normal operation, thehot surface igniter 102 may be turned on, etc., to start, initiate, etc., a combustion process of the furnace (e.g., in response to a thermostat call for heat, etc.). - The igniter
failure detection assembly 100 also includes an igniter relay 104 (e.g., anigniter drive relay 104, etc.) coupled to thehot surface igniter 102. Theigniter relay 104 is adapted to selectively supply a current to thehot surface igniter 102 based on a state of theigniter relay 104. - For example, as illustrated in
FIG. 1 , theigniter relay 104 is coupled between avoltage source 105 and thehot surface igniter 102. Thevoltage source 105 may include any suitable source for supplying voltage and/or current to thehot surface igniter 102, including but not limited to, a power supply, a line voltage input, a utility grid voltage supply, etc. For example, in some embodiments, thevoltage source 105 may include about a 110 volt alternating current (VAC) supply. - The
relay 104 is selectively turned on and off (e.g., opened and closed, etc.) via a control signal, which may be provided bycontroller 108 inFIG. 1 , may be provided by another controller (e.g., furnace controller, thermostat, etc.) which is not shown inFIG. 1 , etc. For example, therelay 104 may be turned on (e.g., closed, etc.) in response to a call for initiation or startup of a combustion process of the furnace (e.g., a call for heat, etc.), where therelay 104 starts to supply current and/or voltage from thevoltage source 105 to thehot surface igniter 102. Therelay 104 may include any suitable relay element, switch element, etc., capable of selectively providing current from thevoltage source 105 to thehot surface igniter 102. - As shown in
FIG. 1 , aresistor 106 is coupled in parallel with thehot surface igniter 102. Thus, anode 110 is defined between theigniter relay 104, thehot surface igniter 102 and theresistor 106. As mentioned above, theresistor 106, coupled in parallel with thehot surface igniter 102, allows for detection of fault conditions of thehot surface igniter 102. For example, a resistance value of theresistor 106 may be sufficiently greater than a resistance value of thehot surface igniter 102 during normal operation. Therefore, when thehot surface igniter 102 is operating properly (e.g., a normal operating condition of the hot surface igniter, etc.), an equivalent resistance of the parallel-coupledresistor 106 and thehot surface igniter 102 may correspond to the resistance of thehot surface igniter 102 during normal operation, because the normal operating resistance of thehot surface igniter 102 is sufficiently less than the resistance value of theresistor 106. - In some embodiments, the resistance of the hot surface igniter 102 during normal operating conditions may be less than about fifty ohms (e.g., about thirty ohms, etc.), and a resistance value of the
resistor 106 may be more than about fifty ohms (e.g., about 500 k ohms, etc.). As should be apparent, these resistance values are provided as only one example, and other embodiments may use any other suitable resistance values sufficient to distinguish resistance of theresistor 106 from resistance of thehot surface igniter 102 during normal operation, etc. - As described above, when the
hot surface igniter 102 is operating properly the equivalent resistance of the parallel-coupledresistor 106 and thehot surface igniter 102 will correspond to a resistance value of thehot surface igniter 102 during normal operation (e.g., about thirty ohms, etc.). In contrast, during a fault condition of the hot surface igniter 102 (e.g., where thehot surface igniter 102 is not operating properly, is not turning on, etc.) the equivalent resistance of the parallel-coupledresistor 106 and thehot surface igniter 102 will correspond to the resistance value of theresistor 106. This is due to the fact that a faultyhot surface igniter 102 may have an approximately infinite resistance (e.g., open circuit, resistance value that is much higher than the resistance value ofresistor 106, etc.). - Therefore, detection of the equivalent resistance of the parallel-coupled
resistor 106 and thehot surface igniter 102 allows for determination of whether thehot surface igniter 102 has failed (e.g., is experiencing a fault condition, etc.). As shown inFIG. 1 , acontroller 108 is coupled to thenode 110 defined between theigniter relay 104, theresistor 106 and thehot surface igniter 102. - The
controller 108 is configured to detect a voltage at thenode 110 to determine whether a fault condition of thehot surface igniter 102 exists. For example, the voltage atnode 110 may correspond to the equivalent resistance of the parallel-coupledresistor 106 and thehot surface igniter 102. Therefore, when the detected node voltage corresponds to a normal operation resistance value of the hot surface igniter 102 (e.g., less than about fifty ohms, about thirty ohms, etc.), the detected node voltage is indicative of a normal operating hot surface igniter. In contrast, when the detected node voltage corresponds to a resistance value of the resistor 106 (e.g., more than about fifty ohms, about 500 k ohms, etc.), the detected node voltage is indicative of a fault condition of thehot surface igniter 102. - The
controller 108 may be configured to perform operations using any suitable combination of hardware and software. For example, thecontroller 108 may include any suitable circuitry, logic gates, microprocessor(s), computer-executable instructions stored in memory, etc., operable to cause thecontroller 108 to perform actions described herein (e.g., determining fault conditions of thehot surface igniter 102, etc.) - As should be apparent, a correspondence relationship between the detected voltage at
node 110 and the equivalent resistance of the parallel-coupledresistor 106 and thehot surface igniter 102 may be determined based on values, parameters, etc., of the components coupled in the igniterfailure detection assembly 100. For example, a low voltage value atnode 110 may correspond to low equivalent resistance of the parallel-coupledresistor 106 and the hot surface igniter 102 (e.g., indicative of normal operation ofhot surface igniter 102, etc.). A high voltage value atnode 110 may correspond to high equivalent resistance of the parallel-coupledresistor 106 and the hot surface igniter 102 (e.g., indicative of a fault condition of thehot surface igniter 102, etc.). As should be apparent, a high voltage value, a low voltage value, etc., atnode 110 may be determined based on resistances of components coupled tonode 110 in the igniterfailure detection assembly 100. In some embodiments, the components may be coupled such that a low voltage value atnode 110 is indicative of a high equivalent resistance of the parallel-coupledresistor 106 and thehot surface igniter 102, a high voltage value atnode 110 is indicative of a low equivalent resistance of the parallel-coupledresistor 106 and thehot surface igniter 102, etc. -
FIG. 2 illustrates another exemplary embodiment of an igniterfailure detection assembly 200. The igniterfailure detection assembly 200 is similar to theassembly 100 illustrated inFIG. 1 , but further includes aflame sensor 212. - The
flame sensor 212 is adapted to sense a presence or absence of flame in the furnace. For example, theflame sensor 212 may detect whether combustible gas of the furnace has been properly ignited in response to initiation of a combustion process of the furnace. If theflame sensor 212 does not detect a presence of a flame generated in response to a startup, initiation, etc., of the combustion process of the furnace, theflame sensor 212 may indicate a fault condition of one of theigniter relay 104 and thehot surface igniter 102. - As shown in
FIG. 2 , thecontroller 108 is coupled to theflame sensor 212 to receive a signal indicative of the presence or absence of a flame, as detected by theflame sensor 212. Thecontroller 108 may use the detected flame sensor signal to determine when the furnace is operating properly. For example, if thecontroller 108 detects an absence of a flame via theflame sensor 212 after a combustion process of the furnace has been initiated, thecontroller 108 may detect a voltage atnode 110 to determine which component(s) of the igniterfailure detection assembly 100 are experiencing a fault condition (e.g., theigniter relay 104, thehot surface igniter 102, etc.). - When the
controller 108 detects an absence of a flame and the detected node voltage corresponds to the normal operation resistance value of thehot surface igniter 102, thecontroller 108 may determine a fault condition of theigniter relay 104. When thecontroller 108 detects an absence of a flame and the detected node voltage corresponds to the resistance value of thehot surface igniter 102, thecontroller 108 may determine a fault condition of thehot surface igniter 102. -
FIG. 3 illustrates another exemplary embodiment of an igniterfailure detection assembly 300. Similar to theassemblies FIGS. 1 and 2 , the igniterfailure detection assembly 300 includes ahot surface igniter 302 coupled in parallel with aresistor 306. Anigniter relay 304 is coupled to thehot surface igniter 302 to provide a current to thehot surface igniter 302. For example, when the inducer relay 314 (e.g., an inducer drive relay, etc.) is in a closed state and theigniter relay 304 is in a closed state, theigniter relay 304 may supply current to thehot surface igniter 302 from the 110 VAC line voltage input. - As shown in
FIG. 3 , the igniterfailure detection assembly 300 also includes aninducer relay 314 coupled between the 110 VAC line voltage input and theigniter relay 304. Theinducer relay 314 may be adapted to provide the 110 VAC line voltage input toigniter relay 304 and an inducer (not shown) of the furnace to operate the inducer, etc. - The igniter
failure detection assembly 300 also includes anotherresistor 316 coupled in parallel with theigniter relay 304. Theresistor 316 may have a resistance value that is substantially the same as the resistance value of theresistor 306 coupled in parallel with thehot surface igniter 302. - As shown in
FIG. 3 , anode 310 is defined between theigniter relay 304, theresistor 316, thehot surface igniter 302 and theresistor 306. Thenode 310 is coupled to a microcontroller (not shown) via resistors R3 and R4. This allows the microcontroller to detect a voltage atnode 310 to determine a fault condition of theigniter relay 304, thehot surface igniter 302, etc. - For example, when the
inducer relay 314 and theigniter relay 304 are both on and thehot surface igniter 302 is operating normally, a voltage atnode 310 would be approximately equal to the line voltage. During a warm-up period of thehot surface igniter 302, theinducer relay 314 and theigniter relay 304 are both turned on, and thehot surface igniter 302 is initially off. - The
igniter relay 304 is turned off (e.g., in an off-state, etc.) when thehot surface igniter 302 is required to be off (e.g., no current call forhot surface igniter 302 operation, etc.). Theigniter relay 304 is turned on (e.g., in an on-state, etc.) when thehot surface igniter 302 is required to be on (e.g., a call forhot surface igniter 302 operation, etc.). The voltage atnode 310 and the call status (e.g., on or off software status, control signal, etc.) forigniter relay 304 are used to identify whether thehot surface igniter 302 is faulty and/or theigniter relay 304 is faulty. - In some embodiments, the voltage at
node 310 may have one of at least three discrete values (e.g., approximately equal to the line voltage, approximately equal to half of the line voltage, and approximately equal to zero).FIG. 4 includes achart 400 illustrating example voltages atnode 310 during both an igniter relay on-state and an igniter relay off-state, and the fault conditions indicated by the respective node voltages. - When the
inducer relay 314 is on and theigniter relay 304 is set to off by the controller, the voltage atnode 310 should be approximately zero volts. As shown inFIG. 4 , if the controller detects a voltage atnode 310 of approximately zero volts when theinducer relay 314 is on and theigniter relay 304 is set to off, the controller may determine that no fault condition exists. Therefore,igniter relay 304 andhot surface igniter 302 may be operating in normal (e.g., healthy, etc.) conditions (e.g., a hot surface igniter resistance of approximately thirty ohms, etc.). - If the controller detects a voltage at
node 310 of approximately half of the line voltage (i.e., LV/2) when theinducer relay 314 is on and theigniter relay 304 is set to off by the controller, the controller may determine that thehot surface igniter 302 is faulty (e.g., is open, has a fault condition, etc.). - If the controller detects a voltage at
node 310 approximately equal to the line voltage (i.e., LV) when theinducer relay 314 is on and theigniter relay 304 is set to off by the controller, the controller may determine that theigniter relay 304 is stuck in a closed state, experiencing a fault condition, etc. For example, no change in feedback voltage fromnode 310 when the igniter relay status is set to off may indicate theigniter relay 304 is stuck in a closed state. - As shown in
FIG. 4 , when theinducer relay 314 is on and theigniter relay 304 is set from the off-state to the on-state by the controller, if the voltage atnode 310 is approximately equal to the line voltage (e.g., LV) the controller may not be able to identify a fault related to theigniter relay 304 and thehot surface igniter 302. - If the controller detects a voltage at
node 310 of approximately half of the line voltage (i.e., LV/2) when theinducer relay 314 is on and theigniter relay 304 status is set from off to on by the controller, the controller may determine that theigniter relay 304 is faulty (e.g., stuck in an open position, etc.) and thehot surface igniter 302 is faulty (e.g., is open, has a fault condition, etc.). If theigniter relay 304 is turned on without a fault, the voltage atnode 310 should be approximately equal to the line voltage. - If the controller detects a voltage at
node 310 of approximately zero volts when theinducer relay 314 is on and theigniter relay 304 status is set from off to on by the controller, the controller may determine that theigniter relay 304 is faulty (e.g., is open, has a fault condition, etc.). For example, no change in feedback voltage fromnode 310 when the igniter relay status is set from on to off may indicate theigniter relay 304 is stuck in a closed state. As above, if theigniter relay 304 is turned on without a fault, the voltage atnode 310 should be approximately equal to the line voltage. - The voltage at
node 310 will be determined based on the resistance value ofresistor 306, and a resistance value of thehot surface igniter 302. As mentioned above, thehot surface igniter 302 may have an approximately infinite resistance (e.g., open circuit, etc.) during a fault condition of thehot surface igniter 302, and may have a low resistance value (e.g., less than about fifty ohms, about thirty ohms, about fifteen ohms, etc.) when thehot surface igniter 302 is working properly. - The voltage at
node 310 is fed to a microcontroller, optionally via a conditioning circuit (e.g., resistors, etc.), that may adjust the voltage signal within a range suitable for the microcontroller input. - When the
igniter relay 304 is stuck in an open position, voltage atnode 310 would be the same as if theigniter relay 304 were purposefully turned off. If theigniter relay 304 is stuck in a closed position, voltage atnode 310 would be the same as if theigniter relay 304 were purposefully turned on. This allows determination of the correct fault detection while operating theigniter relay 304. - The example igniter fault detection assemblies described herein may be included in any suitable HVAC system, etc. The igniter fault detection assemblies described herein may be part of a furnace of the HVAC system. In some embodiments, the controllers described herein may be furnace controllers, thermostats, etc.
- According to another example embodiment of the present disclosure, a method of detecting a fault condition of a furnace igniter assembly is disclosed. The furnace igniter assembly includes a hot surface igniter adapted to heat up to ignite a combustible gas of the furnace, an igniter relay coupled to the hot surface igniter to selectively supply a current to the hot surface igniter based on a state of the igniter relay, and a resistor coupled in parallel with the hot surface igniter and defining a node between the igniter relay, the resistor and the hot surface igniter. The exemplary method includes initiating a combustion process of the furnace, and detecting a voltage at the node defined between the igniter relay, the resistor and the hot surface igniter. The method further includes determining whether a fault condition of the hot surface igniter exists based on the detected voltage at the node, wherein a detected node voltage corresponding to a normal operation resistance value of the hot surface igniter is indicative of a normal operating hot surface igniter, and a detected node voltage corresponding to a resistance value of the resistor is indicative of a fault condition of the hot surface igniter.
- In some embodiments, the method includes sensing a presence or absence of a flame generated in response to ignition of the combustible gas by the hot surface igniter and determining whether the fault condition of the hot surface igniter exists in response to detection of the absence of a flame after the start of the combustion process of the furnace.
- The method may include, when an absence of a flame is detected after the start of the combustion process of the furnace and the detected node voltage corresponds to the normal operation resistance value of the hot surface igniter, determining that a fault condition of the igniter relay exists. The resistance value of the hot surface igniter is less than about fifty ohms and the resistance value of the resistor is greater than about fifty ohms.
- In some embodiments, the furnace igniter assembly further includes an inducer relay coupled to the igniter relay and a second resistor coupled in parallel with the igniter relay, and the second resistor has a resistance value that is substantially the same as the resistance value of the resistor coupled in parallel with the hot surface igniter. In those cases, the method may include determining whether a fault condition of the igniter relay exists based on the detected node voltage of the node defined between the hot surface igniter and the igniter relay.
- In some embodiments, a temperature sensor may be used to check whether a hot surface igniter is heating properly before determining the hot surface igniter is faulty. Alternatively, or in addition, a current of the hot surface igniter could be measured to check whether the hot surface igniter is operating properly before determining the hot surface igniter is faulty.
- Example embodiments described herein may allow furnace control boards, etc., to detect whether a hot surface igniter is faulty or whether an igniter relay is faulty. This may allow a technician to determine whether a control board should be replaced, or whether only the hot surface igniter needs to be replaced. This may allow for reduced repair time, reduced repair cost, etc.
- Example embodiments are provided so that this disclosure will be thorough, and will fully convey the scope to those who are skilled in the art. Numerous specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be employed, that example embodiments may be embodied in many different forms and that neither should be construed to limit the scope of the disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail.
- The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a”, “an” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “includes,” “including,” “has,” “have,” and “having,” are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. It is also to be understood that additional or alternative steps may be employed.
- When an element or layer is referred to as being “on”, “engaged to”, “connected to” or “coupled to” another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to”, “directly connected to” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
- The term “about” when applied to values indicates that the calculation or the measurement allows some slight imprecision in the value (with some approach to exactness in the value; approximately or reasonably close to the value; nearly). If, for some reason, the imprecision provided by “about” is not otherwise understood in the art with this ordinary meaning, then “about” as used herein indicates at least variations that may arise from ordinary methods of measuring or using such parameters. For example, the terms “generally”, “about”, and “substantially” may be used herein to mean within manufacturing tolerances.
- Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms when used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.
- Spatially relative terms, such as “inner,” “outer,” “beneath”, “below”, “lower”, “above”, “upper” and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. Spatially relative terms may be intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
- The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements, intended or stated uses, or features of a particular embodiment are generally not limited to that particular embodiment, but, where applicable, are interchangeable and can be used in a selected embodiment, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
Claims (20)
1. An igniter failure detection assembly for a furnace, the igniter failure detection assembly comprising:
a hot surface igniter adapted to, in response to receiving a current, heat up to ignite a combustible gas of the furnace;
an igniter relay coupled to the hot surface igniter, the igniter relay adapted to selectively supply a current to the hot surface igniter based on a state of the igniter relay;
a resistor coupled in parallel with the hot surface igniter and defining a node between the igniter relay, the resistor, and the hot surface igniter; and
a controller configured to detect a voltage at the node and determine whether a fault condition of the hot surface igniter exists based on the detected voltage at the node, wherein a detected node voltage corresponding to a normal operation resistance value of the hot surface igniter is indicative of a normal operating hot surface igniter, and a detected node voltage corresponding to a resistance value of the resistor is indicative of a fault condition of the hot surface igniter.
2. The igniter failure detection assembly of claim 1 , further comprising a flame sensor adapted to sense a presence or absence of a flame generated in response to ignition of the combustible gas by the hot surface igniter.
3. The igniter failure detection assembly of claim 2 , wherein the controller is coupled to the flame sensor and is configured to detect the presence or absence of a flame via the flame sensor.
4. The igniter failure detection assembly of claim 3 , wherein the controller is configured to determine whether the fault condition of the hot surface igniter exists in response to detection of the absence of a flame after the start of a combustion process of the furnace.
5. The igniter failure detection assembly of claim 4 , wherein the controller is configured to, when the controller detects an absence of a flame and the detected node voltage corresponds to the normal operation resistance value of the hot surface igniter, determine a fault condition of the igniter relay.
6. The igniter failure detection assembly of claim 1 , wherein the resistance value of the hot surface igniter is less than about fifty ohms.
7. The igniter failure detection assembly of claim 1 , wherein the resistance value of the resistor is greater than about fifty ohms.
8. The igniter failure detection assembly of claim 7 , wherein the resistance value of the resistor is greater than or equal to about 500 thousand ohms.
9. The igniter failure detection assembly of claim 1 , wherein the igniter relay is coupled to a line voltage input and is adapted to selectively supply the line voltage input to the hot surface igniter based on the state of the igniter relay.
10. The igniter failure detection assembly of claim 9 , wherein the line voltage input is approximately 110 volts alternating current (VAC).
11. The igniter failure detection assembly of claim 9 , further comprising:
an inducer relay coupled between the line voltage input and the igniter relay; and
a second resistor coupled in parallel with the igniter relay, the second resistor having a substantially similar resistance value as the resistor coupled in parallel with the hot surface igniter.
12. The igniter failure detection assembly of claim 11 , wherein, when a status of the igniter relay is set to off, the controller is configured to:
when the detected node voltage is equal to about half of the line voltage input, determine a fault condition of the hot surface igniter;
when the detected node voltage is about equal to the line voltage input, determine the igniter relay is stuck in a closed position; and
when the detected node voltage is about zero, determine a normal operation condition of the hot surface igniter and the igniter relay.
13. The igniter failure detection assembly of claim 11 , wherein, when a status of the igniter relay is set to on, the controller is configured to:
when the detected node voltage is equal to about half of the line voltage input, determine a fault condition of the hot surface igniter and that the igniter relay is stuck in an open position; and
when the detected node voltage is about zero, determine the igniter relay is stuck in an open position.
14. The igniter failure detection assembly of claim 1 , further comprising a conditioning circuit coupled between the node and the controller to adjust the detected node voltage within a range suitable for the microcontroller input.
15. An HVAC system including a furnace having the igniter failure detection assembly of claim 1 , wherein the controller comprises a furnace controller of the furnace.
16. A method of detecting a fault condition of a furnace igniter assembly, the furnace igniter assembly including a hot surface igniter adapted to heat up to ignite a combustible gas of the furnace, an igniter relay coupled to the hot surface igniter to selectively supply a current to the hot surface igniter based on a state of the igniter relay, and a resistor coupled in parallel with the hot surface igniter and defining a node between the igniter relay, the resistor and the hot surface igniter, the method comprising:
initiating a combustion process of the furnace;
detecting a voltage at the node defined between the igniter relay, the resistor and the hot surface igniter; and
determining whether a fault condition of the hot surface igniter exists based on the detected voltage at the node, wherein a detected node voltage corresponding to a normal operation resistance value of the hot surface igniter is indicative of a normal operating hot surface igniter, and a detected node voltage corresponding to a resistance value of the resistor is indicative of a fault condition of the hot surface igniter.
17. The method of claim 16 , further comprising sensing a presence or absence of a flame generated in response to ignition of the combustible gas by the hot surface igniter, and determining whether the fault condition of the hot surface igniter exists in response to detection of the absence of a flame after the start of the combustion process of the furnace.
18. The method of claim 17 , further comprising, when an absence of a flame is detected after the start of the combustion process of the furnace and the detected node voltage corresponds to the normal operation resistance value of the hot surface igniter, determining that a fault condition of the igniter relay exists.
19. The method of claim 16 , wherein the resistance value of the hot surface igniter is less than about fifty ohms and the resistance value of the resistor is greater than about fifty ohms.
20. The method of claim 16 , wherein the furnace igniter assembly further includes an inducer relay coupled to the igniter relay and a second resistor coupled in parallel with the igniter relay, and the second resistor has a resistance value that is substantially the same as the resistance value of the resistor coupled in parallel with the hot surface igniter, the method further comprising:
determining whether a fault condition of the igniter relay exists based on the detected node voltage of the node defined between the hot surface igniter and the igniter relay.
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US15/916,868 Abandoned US20180306445A1 (en) | 2017-04-22 | 2018-03-09 | Igniter failure detection assemblies for furnaces, and corresponding methods of detecting igniter failure |
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Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
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US11781752B2 (en) | 2021-06-23 | 2023-10-10 | Copeland Comfort Control Lp | Using diode rectification to determine igniter, inducer relay, and igniter relay faults |
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