BOILER, BOILER ASSEMBLY, AND WATER HEATING SYSTEM

FIELD OF THE INVENTION

This disclosure relates to a boiler, boiler assembly, and water heating system configured for use with an indirect water heater and a hydronic space heating system.

BACKGROUND OF THE INVENTION

A conventional hydronic heater system includes a boiler and one or more space heat zones with radiators plumbed to the boiler inlet/outlet. During a heat demand from the space heater zones, water flowing through the heat exchanger of the boiler is heated by the boiler heat source (e.g. gas burner) and is pumped through the radiators of the space heat zones via piping. In conventional hydronic water heater systems, the boiler controller manages both space heating and domestic hot water (DHW) production.

There remains a need for an improved boiler, boiler assembly, or water heating system for producing domestic hot water and space heating production.

SUMMARY OF THE INVENTION

A boiler configured for use with an indirect water heater and a hydronic space heating system, the boiler comprising a boiler water inlet configured to be fluidly connected to an indirect water heater water outlet of the indirect water heater and to a hydronic space heating water outlet of the hydronic space heating system, a boiler water outlet fluidly connected to the boiler water inlet and configured to be fluidly connected to an indirect water heater water inlet of the indirect water heater and to a hydronic space heating water inlet of the hydronic space heating system, a boiler heat exchanger interposed between the boiler water inlet and the boiler water outlet, a heat source providing heat to the boiler heat exchanger, and a controller configured to activate water flow between the boiler heat exchanger, the indirect water heater exchanger, and the hydronic space heating system, activate the heat source to provide heat to the boiler heat exchanger at a firing rate, compare the firing rate to a predetermined firing rate, and adjust the water flow based on a simultaneous heat demand from the hydronic space heating system and the indirect water heater based on a result of the comparing the firing rate to the predetermined firing rate.

A boiler comprising a boiler water inlet, a boiler water outlet, a boiler heat exchanger interposed between the boiler water inlet and the boiler water outlet, a heat source configured to provide heat to the boiler heat exchanger, a carbon dioxide gas sensor configured to detect a value of carbon dioxide inside a boiler cabinet during burner operation, and a controller configured to activate the heat source at a predetermined firing rate, maintain firing of the heat source at the predetermined firing rate for a predetermined time period, during the predetermined time period monitor the value of carbon dioxide based on a signal transmitted from the carbon dioxide gas sensor, compare the value of carbon dioxide to a selected value of carbon dioxide, and when the value of carbon dioxide exceeds the selected value of carbon dioxide, adjust the predetermined firing rate to a reduced firing rate.

A kit for a boiler assembly, the kit comprising a boiler contained in a package assembly, a stand component contained in the package assembly, the stand component being configured to be coupled to the boiler, and a packaging component of the package assembly, the packaging component being sized to support the boiler or the stand component during assembly of the stand component to the boiler upon removal of the boiler, the stand component, and the packaging component from the package assembly.

A method for assembling a stand to a boiler, the method comprising removing a boiler from a package assembly, removing a stand component from the package assembly, removing a packaging component from the package assembly, supporting the boiler or the stand component with the packaging component, and coupling the stand component to the boiler.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawing figures depict one or more implementations, by way of example only, not by way of limitation. In the figures, like reference numerals refer to the same or similar elements.

FIG. 1 is a block diagram of an embodiment of a plumbing configuration of a hydronic heater system according to an aspect of the disclosure.

FIG. 2A is a block diagram of an embodiment of an electrical configuration of a hydronic heater system according to an aspect of the disclosure.

FIG. 2B illustrates the location of dip switches at the bottom of the Printed Circuit Board of the control board of a hydronic heater system according to an aspect of the disclosure.

FIG. 2C is a schematic diagram of a plumbing configuration of a hydronic heater system according to an aspect of the disclosure.

FIG. 2D is a schematic diagram of a plumbing configuration of a cascade-connected hydronic heater system with separate control of space heating and DHW heating according to an aspect of the disclosure.

FIG. 3 is a flowchart describing an operation of an embodiment of a hydronic heater system according to an aspect of the disclosure.

FIG. 4 is a more detailed flowchart describing a more detailed operation of the embodiment of the hydronic heater system in FIG. 3 according to an aspect of the disclosure.

FIG. 5 illustrates the flow paths and characteristics in zone heating mode and DHW mode of an embodiment of a boiler according to an aspect of the disclosure.

FIG. 6 illustrates the components of the boiler illustrated in FIG. 5.

FIG. 7 is a flowchart describing an operation of an embodiment of a hydronic heater system with CO₂sensor implementation according to an aspect of the disclosure.

FIG. 8 is a perspective view that illustrates the components of an embodiment of a boiler assembly according to an aspect of the disclosure.

FIGS. 9-20 illustrate a kit with a package assembly for transporting a boiler and a method for assembling a floor stand to a boiler according to an aspect of the disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

When there is concurrent or overlapping demand for space heating and domestic hot water, space heating can be paused while domestic hot water is being produced. However, if domestic hot water is being used over an extended period of time, space heating comfort may be compromised. According to one aspect, this invention makes it possible to simultaneously produce domestic hot water and space heating when the domestic hot water production does not need the full input of the boiler.

FIG. 1 is a block diagram of an embodiment of a plumbing configuration of hydronic heater system. Included in the system is boiler 100 and hydronic space heat radiators in one or more space heat zones 116 and 118 that are plumbed together. In addition to space heat zones 116 and 118, other heater appliances such as indirect water heater 112 supplying hot water, herein referred to as domestic hot water (DHW), may also be plumbed with the boiler. Space heating calls may be controlled in conjunction with an outdoor sensor (not show) which establishes a relationship between an outdoor temperature and a boiler water temperature.

During operation, boiler 100 is triggered to produce hot water in response to a heat demand signal received from zone controller 103, which is connected to respective thermostats (not shown) and connected to zone pumps of space heat zone 116 and/or space heat zone 118. The indirect hot water heater is controlled by either an aquastat or DHW sensor and pump 128 that are all connected to boiler controller 102. Boiler controller 102 may have 2 electrical contacts: 1 for space heating and 1 for DHW via various temperature sensing devices (e.g. sensors, thermostats, aquastats, etc.). Upon being triggered by zone controller 103, boiler controller 102 controls heat source 104 (e.g. gas burner, electric element, etc.) to fire and heat water in heat exchanger 106.

In the case of a gas burner, a valve may release the gas, at which point a burner fan (not shown) applies positive air pressure to the system to suck an amount of gas from the valve that is proportional the burner fan speed (e.g. if the firing rate is high, then the fan speed will be high and the amount of gas sucked out and ignited will be high thereby producing high heat for the boiler; if the firing rate is low, then the fan speed will be low and the amount of gas sucked out and ignited will be low thereby producing low heat for the boiler). During this procedure, zone controller 103 also controls one or more of pumps 130 and/or 132 to start pumping heated water from boiler outlet 111 through the system appliances and back to boiler inlet 109. Valves 120, 124 and 126 may also be controlled by zone controller 103, or they may be manual valves that are normally open. For example, if a heat demand is received from space heat zone 116, boiler controller 102 fires heat source 104 and zone controller 103 turns on pump 132 to force hot water from the boiler heat exchanger 106 to radiators (not shown) in space heat zone 116. Likewise, if a heat demand is received from space heat zone 118, boiler controller 102 fires heat source 104 and zone controller 103 turns on pump 130 to force hot water from the boiler heat exchanger 106 to radiators (not shown) in space heat zone 118. In yet another example, if a heat demand is received from indirect water heater 112, boiler controller 102 fires heat source 104 and boiler controller 102 turns on pump 128 to force hot water from the boiler heat exchanger 106 to heat exchanger 114 of indirect water heater 112. In either case, once the heat demands are satisfied, boiler controller 102 is able to reduce or turn off the firing rate of heat source 104 independently, or in response to a shutoff command from zone controller 103.

Generally, boiler 100 supplies hot water to indirect water heater 112, space heat zone 116 and space heat zone 118 either one at a time or simultaneously by controlling the firing rate of the heat source 104 and the operational state of pumps 130-132 with the aid of zone controller 103. Firing rate generally dictates the amount of heat produced by heat source 104 (e.g. gas flow volume for a gas burner, electrical current flowing through an electric heater element, etc.). This may be measured in percentage of a maximum amount of heat or the maximum firing rate (e.g. British Thermal Units (BTUs)) that can be produced from heat source 104 (e.g. 0%-100%).

FIG. 2A is block diagram of an embodiment of an electrical configuration of the hydronic heater system shown in FIG. 1. In general, controller 200, which includes a separate or a combined boiler controller 102 and zone controller 103, may include a processor and other supporting electronic devices such as memory, input/output ports, etc., and may be connected to various electrical devices (e.g. pumps, thermostats, etc.) for supporting the control of the hydronic heater system shown in FIG. 1. For example, controller 200 may be electrically connected via electrical wires to thermostats and sensors 202 (e.g. aquastat/DHW sensor (thermostat) of the indirect water heater, thermostats of the space heat zones, inlet/outlet temperature/flow sensors of the boiler, etc.), pumps 204, water valves 206, heat source 208 and user interface 210. These electrical connections allow controller 200 to receive/send electrical signals to/from the various electrical devices in the system.

Boiler 100 provides a DHW Smart Priority functionality. This technology evaluates operating conditions and allows for simultaneous domestic water and space heating production when the domestic water production does not need the full input of the boiler. During “Smart Priority” mode, boiler 100 can supply heat to both the hydronic heat zones 116 and/or 118 (e.g., Central Heat) and DHW loads unless the firing rate exceeds a predetermined level. If the firing rate exceeds a predetermined level, DHW will be prioritized by shutting down of the boiler pump 128 until either the demand for DHW is satisfied, or the boiler firing rate drops below a lower predetermined level. “Smart Priority” mode is designed to reduce rapid burner cycling and reduce operation of boiler 100 at a maximum firing rate.

“Smart Priority” mode can be enabled on boiler 100 by setting a dip switch 3 (FIG. 2B) to an ON position. When dip switch 3 is set to “Smart Priority,” boiler controller 102 that controls DHW production can operate simultaneously for both space heating and DHW loads until its firing rate exceeds 80% of the firing rate. Then, boiler controller 102 shuts down zone pumps 130-132 and runs only its DHW pump 128. This feature reduces rapid cycling of the heat source 104 (e.g. gas burner, electric element, etc.), avoids the boiler running up to high limit resulting in longer burner run times at lower firing rates and reduced thermal stress on the heat exchanger 106. Once the firing rate drops below 50%, boiler controller 102 turns on zone pumps 130-132 again, provided zone heat demand is still present and the boiler temperature does not exceed the desired zone heat temperature range.

FIG. 2C is a schematic diagram of a plumbing configuration of a hydronic heater system according to an aspect of the disclosure. Boiler 100 has two heating zone inputs. Two independent heating curves may be programmed for each input. Parameters P6, P7 and P40, P41 can be used to adjust the heating curves for T/T and L-T/T respectively. The boiler can provide the appropriate temperature based upon which zone has a demand for heat. If both zones have heat demand, the boiler defaults to the target temperature set for the T/T zone. The L-T/T zone is designed for a lower operating temperature. The boiler can control a 24 V mixing valve motor and has a mixed temperature sensor input. Each of the two inputs (T/T and L-T/T) have corresponding pump relays. Pumps are wired to the corresponding 120V output terminals. Turning P42 (MI) to ON enables 24 V mixing valve operation. The DHW zone will have priority over the CH and L-CH zones provided Regular Priority is selected. In case “Smart Priority” is selected, the boiler will discontinue to supply heat to the CH and L-CH circuit once the boiler firing rate exceeds 80%. Once the firing rate drops below 50%, the control will energize the boiler pump (P1) again.

FIG. 2D is a schematic diagram of a plumbing configuration of a cascade-connected hydronic heater system with separate control of space heating and DHW heating. Up to four boilers can be connected in cascade, such that the output of one of the boilers is the input to the next boiler. As illustrated in FIG. 2D, boilers B1-B4 are connected in cascade. In addition, boiler B1 is set as a leader, while boilers B2-B4 are set as followers. The leader boiler B1 automatically shares all cascade parameters with the other boilers B2-B4. The system parameters only need to be set up on the leader boiler B1. The leader boiler B1 is placed on the right; the cascade sensor is placed on the system side of the low loss header. The heat exchanger in the Indirect Tank is piped as a separate zone to one or both follower boilers. A DHW load is a boiler direct demand. The pump for the indirect tank is powered from the DHW tank terminals. The (dry contact) aquastat or DHW sensor connects back to the DHW sensor terminals of the boiler. The DHW Pumps B2-P4 and B3-P4 are sized for the DHW Indirect flow rate and Total Head Loss through the DHW Indirect coil, piping, and respective boilers' B2 and B3 head loss.

In case “Smart Priority” mode is enabled on boilers B2 and B3 by setting dip switch 3 (FIG. 2B) to ON (which can be the default setting of the boilers), their respective boiler pump P1 can operate during DHW demand. As each boiler's firing rate exceeds 80%, the boiler controller shuts down pump P1 while pump P4 continues to operate. This feature can reduce rapid burner cycling and more gradual heat-up of the boiler. This feature works individually for each boiler connected to a DHW load and allows the boiler plant to provide different water temperatures at the same time. Pump P1 turns ON again once the firing rate drops below 50%. A demand for DHW has priority over the T/T and L-T/T zone heat calls to those boiler(s) that have a DHW load connected to themselves The lead boiler and other follower boilers (except for DHW boilers) will continue to operate for space heating. If “Smart Priority” is selected for boilers B2 and/or B3, these boilers will continue to operate their individual boiler pump P1 during a DHW call until the boiler firing rate exceeds 80%. Boiler pump(s) come ON again once the firing rate drops below 50%.

FIG. 3 is a flowchart describing an operation of an embodiment of a hydronic heater system where there is an active DHW demand followed by a hydronic heat demand also referred to as zone heat (ZH) demand. In step 300 there is an active DHW heat demand received from the thermostat (e.g. aquastat or DHW temperature sensor) of indirect water heater 112. In response to this DHW heat demand, in step 302, boiler controller 102 pumps water from boiler inlet 111 to heat exchanger 114 of indirect water heater 112, and boiler controller 102 controls the boiler to fire at a firing rate. In step 306, if zone controller 103 has not received a hydronic heat demand from the thermostats of the hydronic heat zones 116 and/or 118, the boiler controller 102 continues to control the boiler until the DHW heat demand is satisfied (e.g. the thermostat of indirect water heater 112 indicates that the tank water has reached the desired temperature).

It is noted that using a temperature sensor for DHW sensing allows the system to develop a DHW anticipated tank temp feature whereby the burner shuts off before the tank reaches set point. In this scenario, the pump will continue to operate for a short time to purge excess heat from the boiler into the tank. This is beneficial on milder days to lower boiler temp and reduce standby losses. This process could be optimized to minimize burner operation and maximize purge time to a reasonable extent.

If, however, in step 306, boiler controller 102 has received a hydronic heat demand from the thermostats of the hydronic heat zones 116 and/or 118 via zone controller 103, in step 308, zone controller 103 turns on pumps 130 and/or 132 to pump water through hydronic heat zones 116 and/or 118. In step 310, boiler controller 102 compares the firing rate to a predetermined firing rate.

Then, in step 312, boiler controller 102 uses the comparison to adjust the water flow between the boiler heat exchanger 106, the indirect water heater exchanger 114, and the hydronic heat zones 116 and/or 118. For example, if the firing rate exceeds a first predetermined firing rate (e.g., 80%), then boiler controller 102 determines that the hydronic heat demand is high (e.g. zone is large with many radiators expelling the hydronic heat) and controls the heat source 104 to stop providing heat to the hydronic heat zones 116 and/or 118 and to continue providing heat only to the boiler heat exchanger 106. This ensures that the DHW heat demand and the hydronic heat demand are adequately and simultaneously met by reducing operation of the boiler at the maximum firing rate and reducing rapid burner cycling.

In certain exemplary embodiments, boiler controller 102 controls the heat source 104 to continue providing heat only to the boiler heat exchanger 106 for a period of time between 30 minutes and 60 minutes.

FIG. 4 is a more detailed flowchart describing the operation of an embodiment of the hydronic heater system in FIG. 3. In step 400, an active DHW heat demand is received (DHW demand only), and in step 402, boiler controller 102 performs water flow control to meet the DHW heat demand. In step 404, if a hydronic heat demand is not received, then in step 406, boiler controller 102 determines if the DHW heat demand is satisfied or not. If the DHW heat demand is satisfied, then boiler controller 102 turns off the boiler in step 410. If the DHW heat demand is not satisfied, then boiler controller 102 continues to perform water flow control.

If, however, in step 404, simultaneous hydronic heat demand is received from hydronic heat zones 116 and/or 118 (in addition to an active DHW heat demand), then in step 414, boiler controller 102 compares the firing rate to a first predetermined firing rate. If the firing rate exceeds the first predetermined firing rate, then in step 416, boiler controller 102 determines that the hydronic heat demand is high (e.g. zone is large with many radiators expelling the hydronic heat) and controls the heat source 104 to stop providing heat to the hydronic heat zones 116 and/or 118 and to continue providing heat only to the boiler heat exchanger 106. This ensures that the DHW heat demand and the hydronic heat demand are adequately and simultaneously met by reducing operation of the boiler at the maximum firing rate and reducing rapid burner cycling.

In step 408, boiler controller 102 compares the firing rate to a second predetermined firing rate and determines if the firing rate is below the second predetermined firing rate. If the firing rate is below the second predetermined firing rate, then boiler controller 102 continues to perform water flow control in step 412. When the firing rate is below the second predetermined firing rate, then boiler controller 102 controls the heat source 104 to start providing heat to both to the boiler heat exchanger and the hydronic heat zones 116 and/or 118 simultaneously until heat demand from the hydronic heat zones 116 and/or 118 is present or until the firing rate exceeds the first predetermined firing rate. If the firing rate is not below the second predetermined firing rate, then in step 416, boiler controller 102 controls the heat source 104 to stop providing heat to the hydronic heat zones 116 and/or 118 and to continue providing heat only to the boiler heat exchanger 106.

Turning back to FIG. 1, boiler 100 includes sensor 36 (also shown in FIG. 6) configured to detect Carbone Dioxide (CO₂) flue gas recirculation, which means that boiler 100 might bring flue gases back into the boiler 100. The sensor 36 is operatively connected to boiler controller 102, such that the boiler controller 102 can monitor the value of carbon dioxide based on a signal transmitted from the carbon dioxide gas sensor 36. Based on the signal transmitted from the carbon dioxide gas sensor 36, boiler controller 102 compares the detected value of carbon dioxide to a selected value of carbon dioxide, and when the detected value of carbon dioxide exceeds the selected value of carbon dioxide, boiler controller 102 adjusts the firing rate of boiler 100 to a reduced firing rate. To avoid dangerous situations, the concentration of CO₂in boiler 100 can be limited to its ambient value (about 400 ppm).

FIG. 7 is a flowchart describing an operation of an embodiment of a hydronic heater system with CO₂sensor implementation. In step 700, boiler 100 operates in a normal operation mode (e.g., there is an active DHW heat demand received from the aquastat or DHW temperature sensor) of indirect water heater 112. In response to this DHW heat demand, boiler controller 102 pumps water from boiler inlet 111 to heat exchanger 114 of indirect water heater 112, and boiler controller 102 controls the boiler to fire at a predetermined firing rate.

In step 702, boiler controller 102 resets a timing counter, e.g., when the concentration of CO₂is under a selected value “A” of CO₂in ppm over a time interval “B” in minutes measured from the first time when the value of carbon dioxide exceeds the first selected value A of carbon dioxide, or after resetting boiler 100 after an error (e.g., after “Hard-Lock-Out” discussed below).

In step 704, boiler controller 102 compares the value of carbon dioxide detected by, and transmitted from, the sensor 36 to a first selected value “A” of carbon dioxide. The first selected value “A” of carbon dioxide can be one of 4,000 ppm; 6,000 ppm; 8,000 ppm; or 10,000 ppm, for example. The first selected value “A” of carbon dioxide can also be in the range from 4,000 ppm to 10,000 ppm.

In step 706, if the value of carbon dioxide exceeds the first selected value of carbon dioxide, boiler controller 102 reduces the predetermined firing rate to a first reduced firing rate. The first reduced firing rate is no lower than 30% of the predetermined firing rate (e.g., minimum firing rate) and no higher than 70% of the predetermined firing rate (e.g., maximum firing rate).

In step 708, boiler controller 102 starts a first timer measuring a first time interval B from the first time when the value of carbon dioxide exceeds the first selected value A of carbon dioxide. The maximum duration of the first time interval B can vary depending on the first selected value A of carbon dioxide. For example, the maximum duration of the first time interval B can be 5 minutes when the first selected value A of carbon dioxide is in a range of 1,000 ppm to 4,000 ppm. The maximum duration of the first time interval B can be 4 minutes when the first selected value A of carbon dioxide is in a range of 4,001 ppm to 6,000 ppm. The maximum duration of the first time interval B can be 2 minutes when the first selected value A of carbon dioxide is in a range of 6,001 ppm to 8,000 ppm. The maximum duration of the first time interval B can be 1 minute when the first selected value A of carbon dioxide is in a range of 8,001 ppm to 10,000 ppm. In other words, the maximum duration of the first time interval B is higher for lower ranges of the first selected value A of carbon dioxide.

In step 710, boiler controller 102 checks whether the detected value of carbon dioxide exceeds the first selected value A of carbon dioxide and whether the maximum duration of the first time interval B exceeds the corresponding maximum duration of the first time interval B for the first selected value A of carbon dioxide. For example, boiler controller 102 can check whether the detected value of carbon dioxide exceeds 4,000 ppm (e.g., when the first selected value A of carbon dioxide is in a range of 1,000 ppm to 4,000 ppm) for a period of time longer than 5 minutes, which is the maximum duration of the first time interval B when the first selected value A of carbon dioxide is in a range of 1,000 ppm to 4,000 ppm.

If the detected value of carbon dioxide exceeds the first selected value A of carbon dioxide and if the maximum duration of the first time interval B exceeds the corresponding maximum duration of the first time interval B for the first selected value A of carbon dioxide, then in step 712, boiler controller 102 increments a first counter “C” as an “event counter” for high CO₂occurrences. The value of the first counter C can vary depending on the detected value of carbon dioxide. For example, the value of the first counter C can be 1 when the detected value of carbon dioxide is 4,000 ppm. The value of the first counter C can be 2 when the detected value of carbon dioxide is 6,000 ppm. The value of the first counter C can be 3 when the detected value of carbon dioxide is 8,000 ppm. The value of the first counter C can be 4 when the detected value of carbon dioxide is 10,000 ppm. In other words, the value of the first counter C is higher for higher values (or ranges) of the detected value of carbon dioxide.

In certain exemplary embodiments, boiler controller 102 can be configured to accumulate the values of the first counter C to determine a value of an overall accumulation counter C. When the sum of the values of the first counter C to the value of the accumulation trigger level D exceeds a predetermined trigger value, boiler controller 102 can be configured to reduce the predetermined firing rate to the second reduced firing rate (e.g., no lower than 30% of the predetermined firing rate and no higher than 50% of the predetermined firing rate). This approach is designed to reduce the level and occurrences of high CO₂emissions.

In step 714, boiler controller 102 calculates an accumulated trigger occurrence (or count) level C based on the value of carbon dioxide, and compares the value of the accumulated trigger count level D to a predetermined value of the trigger occurrence count level D for acting based on the specific level of carbon dioxide. The value of the predetermined trigger occurrence count level D* can be one of 1000, 2000, or 3000, for example.

In step 716, if the value of the accumulated trigger count level C exceeds the predetermined value (e.g., 2000) of the trigger occurrence count level D, boiler controller 102 reduces the predetermined firing rate to a second reduced firing rate. The second reduced firing rate is no lower than 30% of the predetermined firing rate (e.g., minimum firing rate) and no higher than 50% of the predetermined firing rate (e.g., maximum firing rate). If the value of the accumulated trigger count level D does not exceed the predetermined value (e.g., 2000) of the trigger occurrence count level D, boiler controller 102 continues to monitor the signal transmitted from sensor 36 and to compare the value of carbon dioxide detected by, and transmitted from, the sensor 36 to the first selected value A of carbon dioxide (step 704).

In step 718, if the detected value of carbon dioxide exceeds the first selected value A and the value of the accumulated trigger count level C exceeds the predetermined value of the trigger occurrence count level D for Step 3 (e.g., 3000), then boiler controller 102 performs a “Hard-Lock-Out” of boiler 100 and reduces the firing rate to the second reduced firing rate (e.g., no lower than 30% of the predetermined firing rate and no higher than 50% of the predetermined firing rate). If the detected value of carbon dioxide does not exceed the levels for Step 3, boiler controller 102 continues to monitor the signal transmitted from sensor 36 and to compare the value of carbon dioxide detected by, and transmitted from, the sensor 36 to the second selected value D of carbon dioxide (step 714).

If the detected value of carbon dioxide exceeds the first selected value A and the value of the accumulated trigger count level C exceeds the predetermined value of the trigger occurrence count level D for Step 2 (e.g., 2000), boiler controller 102 performs a “Soft-Lock-Out” of boiler 100 by reducing the firing rate to the second reduced firing rate (e.g., no lower than 30% of the predetermined firing rate and no higher than 50% of the predetermined firing rate) and activating a blinking display, for example, on the user interface 210. The first selected value A for triggering the “Soft-Lock-Out” function of boiler 100 can be selected to be one of 4,000 ppm; 6,000 ppm; 8,000 ppm; or 10,000 ppm; or to be in a range from 4,000 ppm to 10,000 ppm.

In certain exemplary embodiments, boiler 100 can include an outdoor sensor that can detect the current outdoor temperature and transmit a signal to boiler controller 102. The “Hard-Lock-Out” function (step 720 in FIG. 7) preferably utilizes an outdoor sensor on the boiler 100. The “Hard-Lock-Out” function of boiler 100 can be set based on flue gas recirculation accumulator exceeding its critical value (step 718 in FIG. 7) and the outdoor temperature exceeding 35 F. If the value of the current outdoor temperature detected by the outdoor sensor drops below 30 F, boiler controller 102 controls the boiler 100 to resume regular operation. A contractor or boiler installation technician can set the “Hard-Lock-Out” function of boiler 100 to ON if this function is desired.

The boiler 100 described above, and illustrated in the figures, can be mounted to the wall of a building or other confined space. However, boiler 100 can also include an optional floor stand 802, as shown in FIG. 8, for installing boiler 100 on the floor using the stand 802.

Turning now to FIG. 9, boiler 100 can be provided in a kit 900 for transporting the boiler assembly. The kit 900 further includes a package assembly 902 within which boiler 100 is contained. A stand component (e.g., floor stand 802) is also contained in the package assembly 902. The stand component 802 is configured to be coupled to the boiler 100. The stand component 802 includes a plurality of stand components (e.g., a frame, metal bars, fasteners, etc.) configured for assembly into a stand.

The kit 900 further includes a packaging component of the package assembly 902. The packaging component is sized to support the boiler 100 and/or the stand component 802 during assembly of the stand component 802 to the boiler 100 upon removal of the boiler 100, the stand component 802, and the packaging component from the package assembly 902. The packaging component can include a plurality of packaging components, each of which is preferably sized to support the boiler 100 and/or the stand component 802 during assembly of the stand component 802 to the boiler 100.

At least one of the plurality of packaging components is a cardboard box 904. The cardboard box 904 is configured to be lifted in the upward direction off the boiler 100, thereby exposing the boiler 100.

At least one of the plurality of packaging components is a wooden pallet crate 906. The boiler can be coupled during the pallet crate 906 during shipment and transportation.

At least one of the plurality of packaging components is a cushioning packaging component. The cushioning packaging component can be formed from a foamed material such as Styrofoam, for example, although other conventional packaging materials are contemplated as well.

In certain exemplary embodiments, at least two of the plurality of packaging components are cushioning packaging components. At least one of the cushioning packaging components is shaped as a block 1002 (FIG. 10). At least one of the cushioning packaging components is shaped as a sheet 1102 (FIG. 11). The sheet 1102 is configured to be placed within a fold of the cardboard box 904.

At least one dimension of the stand component 802 is equal to or corresponds substantially to the sum of the height of the wooden pallet crate 906 and the thickness of the sheet 1102 placed within the fold of the cardboard box 904.

An overall method for assembling the stand 802 to the boiler 100 includes removing the stand component 802 from the package assembly 902, removing the boiler 100 from the package assembly 902, supporting the boiler 100 or the stand component 802 with a packaging component from the package assembly 902, and coupling the stand component 802 to the boiler 100. The packaging component can be or include cardboard box 904, wooden pallet crate 906, and at least two cushioning packaging components, one of which is shaped as a block 1002 and another one is shaped as a sheet 1102 (FIG. 11).

In more detail, a method for assembling the stand 802 to the boiler 100 includes lifting the cardboard box 904 in the upward direction off the boiler 100, thereby exposing the boiler 100.

The method for assembling the stand 802 to the boiler 100 further includes positioning the cushioning block 1002 next to the boiler 100 (FIG. 12) and tilting the boiler 100 onto the cushioning block 1002 (FIG. 13).

The method for assembling the stand 802 to the boiler 100 further includes folding the cardboard box 904 along the height direction of the cardboard box 904 and placing the sheet 1102 within a fold 904a of the cardboard box 904 (FIG. 14).

The method for assembling the stand 802 to the boiler 100 further includes assembling the plurality of stand components into the stand 802 and placing the assembled stand 802 onto the wooden pallet crate 906 and above the folded cardboard box 904 with the sheet 1102 placed within the fold 904a of the cardboard box 904 (FIG. 16). At least one dimension of the stand component 802 is equal to or corresponds substantially to the sum of the height of the wooden pallet crate 906 and the thickness of the sheet 1102 placed within the fold of the cardboard box 904, which can provide an equal height to the boiler 100 when assembling the floor stand 802 to the boiler 100.

The method for assembling the stand 802 to the boiler 100 further includes removing the folded cardboard box 904 with the sheet 1102 placed within the fold 904a of the cardboard box 904 and the wooden pallet crate 906 from underneath the attached stand 802 (FIG. 17).

The method for assembling the stand 802 to the boiler 100 further includes placing the folded cardboard box 904 with the sheet 1102 placed within the fold 904a of the cardboard box 904 underneath the stand 802, such that an edge of the folded cardboard box 904 with the sheet 1102 placed inside cardboard fold 904a faces the boiler 100 (FIG. 18).

The method for assembling the stand 802 to the boiler 100 further includes lifting the boiler 100 and placing two corners (only corner 1902 is shown in FIG. 19) of the boiler 100 onto the folded cardboard box 904 with the sheet 1102 placed inside the cardboard fold 904a (FIG. 19).

The method for assembling the stand 802 to the boiler 100 further includes walking all corners of the boiler 100 off the folded cardboard box 904 with the sheet 1102 placed inside cardboard fold 904a toward the installation location of the boiler 100 (FIG. 20).

The boiler 100 including the package assembly 902 within which the boiler 100 is contained can weigh in excess of 275 Lbs. However, the method for assembling the stand 802 to the boiler 100 described herein allows assembling, moving, and installation of boiler 100 to be performed by a single person.

It will be understood that the terms and expressions used herein have the ordinary meaning as is accorded to such terms and expressions with respect to their corresponding respective areas of inquiry and study except where specific meanings have otherwise been set forth herein. For example, the term “coupled” as used herein refers to any logical, optical, physical or electrical connection, link or the like by which signals or light produced or supplied by one system element are imparted directly or indirectly to another coupled element. Unless described otherwise, coupled elements or devices are not necessarily directly coupled or connected to one another and may be separated by intermediate components, elements or communication media that may modify, manipulate or carry the signals. Also, the term “coupled” can refer to direct or indirect mechanical or thermal connectedness. Relational terms such as first and second and the like may be used solely to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” “includes,” “including,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises or includes a list of elements or steps does not include only those elements or steps but may include other elements or steps not expressly listed or inherent to such process, method, article, or apparatus. An element preceded by “a” or “an” does not, without further constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element.

Unless otherwise stated, any and all measurements, values, ratings, positions, magnitudes, sizes, and other specifications that are set forth in this specification, including in the claims that follow, are approximate, not exact. Such amounts are intended to have a reasonable range that is consistent with the functions to which they relate and with what is customary in the art to which they pertain. For example, unless expressly stated otherwise, a parameter value or the like may vary by as much as +10% from the stated amount. The term “substantially” as used herein means the parameter value or the like

In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in various examples for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed examples require more features than are expressly recited in each claim. Rather, as the following claims reflect, the subject matter to be protected lies in less than all features of any single disclosed example. Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter.

In the above detailed description, numerous specific details were set forth by way of examples in order to provide a thorough understanding of the relevant teachings. However, it should be apparent to those skilled in the art that the present teachings may be practiced without such details. In other instances, well known methods, procedures, components, and/or circuitry have been described at a relatively high-level, without detail, in order to avoid unnecessarily obscuring aspects of the present teachings.

While the foregoing has described what are considered to be the best mode and/or other examples, it is understood that various modifications may be made therein and that the subject matter disclosed herein may be implemented in various forms and examples, and that they may be applied in numerous applications, only some of which have been described herein. It is intended by the following claims to claim any and all modifications and variations that fall within the true scope of the present concepts.

BOILER, BOILER ASSEMBLY, AND WATER HEATING SYSTEM

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