Patent Application
20090056649
The present invention relates generally to the field of boiler and heating system protection and control.
In the drawings, which constitute a part of this specification, exemplary embodiments are set forth.
In the following description, it is to be understood that the terms used have their ordinary and accustomed meanings in the art, unless otherwise specified. The foregoing description discusses some representative embodiments and is not limiting. Other functions and embodiments will be apparent to those skilled in the art.
Heating systems malfunction and fail for many reasons. These include, e.g., power failure, computer malfunction, high boiler temperature, low boiler temperature, freezing due to low ambient temperature, impeller loss or malfunction, tight bearings or loss of water flow, high or low coil temperature and circulator failure. Repairing or replacing a boiler or furnace can be very expensive. If such problems are discovered immediately, damage to the boiler or heating system and the cost of repair can be minimized or even eliminated altogether. Devices and systems exist to detect or prevent specific causes of boiler malfunction. However, there is no system designed to protect against the wide variety of causes of boiler malfunction or failure. To protect against boiler malfunction for all such causes, one would need to employ many different individual protection systems.
An embodiment provides apparatus and methods for protecting boilers and associated heating systems and preventing damage to the boilers and heating system equipment. A boiler is any unit that generates heat as part of a heating system, and could include a furnace or a steam boiler. A heating system may include a boiler and other components, including but not limited to, water pipes, blowers, circulators, motors, etc. Embodiments can be used to prevent boiler, heating system and enclosure damage by initiating certain actions when a temperature detection event or an ambient temperature detection event occurs. A temperature detection event can include high or low temperature in the boiler or high or low temperature associated with one of the components of the boiler or heating system. An ambient temperature detection event can include high or low temperature in an area of the heating system or associated with one or more of the components of the heating system. An ambient temperature detection event can also include low temperature outside the enclosure to be heated by the boiler or low temperature in a heating zone of the enclosure. A heating zone can be any place in the enclosure to be heated where there is a loop of hot water running through a space. An enclosure can be any structure that separates one space from another space and can include but is not limited to a building, house, factory, office building, room, corridor, etc. More detailed descriptions of temperature detection events are discussed herein. They include, but are not limited to high boiler temperature, low boiler temperature, low ambient temperature outside the enclosure to be heated or in a heating zone of the enclosure and high or low coil temperature.
Embodiments protect the boiler and heating system from damage to due to extreme temperatures, e.g., low temperatures below freezing or high temperature above the top threshold temperature a boiler can withstand. Such temperatures are known to those skilled in the art. The temperature of a hot water boiler should be kept below about 250 degrees Fahrenheit, and the temperature of a steam boiler should be kept below about 212 degrees Fahrenheit. Low temperatures can cause cold water shock to a boiler. Cold water shock is damage to the boiler caused by cold water returning to the boiler from a heating zone and hitting the hot boiler surfaces. Cold water shock can cause cracking of boiler sections. Other potential damage includes, but is not limited to cracked pipes in heating zones, flooding due to boiler section cracking and fires due to overheating of the boiler.
Another embodiment can be used to prevent boiler, heating system and building damage by initiating certain actions when a heating system malfunction occurs. Heating system malfunction broadly includes, but is not limited to boiler or heating system malfunction or failure such as impeller loss or malfunction, tight bearings or loss of water flow and circulator failure. When a temperature detection event occurs or a heating system malfunction or failure occurs, embodiments initiate certain actions to notify the owner of the enclosure to be heated or prevent damage to the boiler and heating system. In some embodiments, these actions include but are not limited to alarm notification, circulating water through the heating system and restoring power from an alternative power source.
Embodiments include various components, which are shown in
An embodiment of the boiler protection apparatus is shown in
The control board monitors the boiler temperature at the sections when the water runs out or evaporates and when the temperature rises above or below normal preset temperature, and some embodiments will trigger signals that ultimately lead the boiler alarm to sound and shut off the boiler. In an embodiment, the control board contains relays 12 and 13, shown in
Embodiments also include a processor 4 shown in
Embodiments may include one or more sensors. The sensors may be temperature sensors and, in particular, high or low temperature sensors 304, 402, 408. In some embodiments, the temperature sensors are type J sensors. Type J sensors produce a signal on the order of millivolts. The sensors may also be water flow or water level sensors 409. These sensors may be vane type sensors inserted in the normal water in which water pushes against the vane to operate the sensor. In one embodiment, the sensor unit includes a water level sensor 409 and and/or a water temperature sensor 408. The sensors may be installed between boiler section or sections 406, 407. The processor 4 as shown in
Such sensors are commercially available, such as the PASPORT™ PS2124 temperature, humidity, and dewpoint sensor, sold by Pasco (www.pasco.com). This unit contains the components necessary to transmit data to a receiver, using radiofrequency (RF) signals, using a Pasco system called XPLORER DATALOGGER™. Various other types of sensors can alternately or additionally be used, if desired, for other types of work. Temperature and humidity sensors (and other types of sensors) that have RF signal-transmitting capability include and utilize a “unique address” system, most commonly a system known as the “MAC” address system. These devices and protocols are well known, and can interact with receiver and/or transmitter systems that are available from companies such as Radiotronix (www.radiotronix.com). These “unique address” systems allow a central unit to identify and correlate each “data set” that is received from any sensor as being from a certain specific sensor, regardless of how many sensors may be active at or near the place of operation.
A second type of sensor may be provided as part of a sensor-switch, which will provide means for determining whether a certain fan, blower, dehumidifier, or other piece of equipment is running, or turned off. This can be done by: (1) plugging a sensor device that contains a current meter (a device that measures electrical current, usually expressed as watts and abbreviated as I) into a wall outlet, extension cord, power strip, or other outlet that will provide 110 or 220 volt alternating current; and, (2) plugging a fan, dehumidifier, or other power equipment into an outlet that is provided and controlled by the sensor-switch 500. If and when a fan, dehumidifier, or other device is turned on and running, the current that powers the device must flow through the sensor-switch, allowing it to measure the current. Accordingly, each sensor-switch can indicate whether a certain piece of equipment is running, or not running. In addition, if a current load becomes unusually high (which indicates that a problem may have arisen or may be approaching), a sensor-switch can trigger an alert or alarm signal, which can activate a pre-programmed response (such as, for example, turning off the power equipment to prevent possible damage, sending an alarm signal to a remote computer or pager, and activating one or more camera or video devices that will begin recording and storing pictures of the job site, to allow a contractor to use a remote computer to see what is happening at the job site). In addition, sensor-switch devices may be provided with on/off switching capability that can be controlled by processor.
The control board 301, 401 receives sensor data from the sensor(s). Some sensors produce digital data. However, for many types of sensors, the sensor data is analog data. Analog sensor data may be converted to digital format by the control board. In one embodiment, the control board evaluates the data received from the sensor(s) and determines whether the data is to be transmitted to the base unit. The sensor unit generally conserves power by not transmitting data that falls within a normal range. In one embodiment, the control board evaluates the sensor data by comparing the data value to a threshold value (e.g., a high threshold, a low threshold, or a high-low threshold). If the data is outside the threshold (e.g., above a high threshold, below a low threshold, outside an inner range threshold, or inside an outer range threshold), then the data is deemed to be anomalous and the control board causes some of the functions described herein. In some embodiments, the data threshold is programmed into the control board.
In an embodiment, shown primarily in
In some embodiments, the apparatus includes a power failure relay 12, shown in
Temperature monitoring relays may also be used in some embodiments. These facilitate the monitoring of excessive or abnormal temperatures outside the predetermined safe temperature ranges for a boiler or heating system. The user can select function settings using a DIP switch. Some such relays have LED indicators to show alarm status. To monitor for overcurrent or undercurrent, a single-phase current relay, shown in
In some embodiments, the boiler protection apparatus prevents damage to the boiler, the heating system and the structure to be heated by the boiler from freezing water due to cold weather by detecting an ambient temperature detection event and sending an alarm notification as discussed herein. In such an embodiment, the ambient sensor 305, 403 is a temperature sensor located outside the building to be heated by the boiler, and a boiler sensor 304, 402 may be attached to the boiler or boiler sensors 408, 409 may be located within the boiler sections 406, 407. The sensors communicate with the processor by way of a 2-wire control when the temperature of the boiler deviates from a predetermined temperature range. The user uses the control board 1, 301, 401 to program into the processor 4 the desired temperature range to prevent freezing. For example, if boiler temperature drops below 40 degrees Fahrenheit, the boiler sensor 304, 402 will send a signal to the processor 4. The temperature could also be set higher at e.g., 50 degrees Fahrenheit, or other temperatures as deemed appropriate by the user. If the boiler is a steam boiler, the boiler sensor 408, 409 may be located in the jacket of the steam boiler or in the water of the steam boiler 400.
In addition, the ambient sensor 305, 403 responds and communicates with the processor 4 within the control board 1, 301, 401 when the outside temperature drops below a predetermined temperature. That temperature would be selected from a range preferably between about 33 degrees Fahrenheit and about 40 degrees Fahrenheit, but could be above 40 degrees Fahrenheit or below 33 degrees Fahrenheit if desired. A temperature should be selected so the ambient sensor responds before the temperature drops low enough to cause the water in the heating system to freeze. This temperature can be adjusted. The sensors are also programmed to respond and signal to the processor when the differential between the boiler temperature and the outside temperature expands beyond a predetermined differential. In some embodiments, the differential may be plus or minus 5 degrees Fahrenheit, but it may vary based on the needs of the user.
Thus, when the outside temperature gets close to freezing and drops below the predetermined temperature programmed into the processor, the ambient sensor 305, 403 communicates the outside temperature to the processor 4. Ambient sensors located in a heating zone can also initiate an alarm if ambient temperature or boiler temperature is too low. Such signals from an ambient sensor turn the control board 1, 301, 401 from a passive mode to a monitoring mode. Passive mode is essentially a stand-by position, which includes monitoring of boiler temperature, but does not include monitoring of circulator function or hydro air temperature. When the control board 1, 301, 401 is in this monitoring mode, the processor 4 then signals the current sensor 313 to monitor the circulators and a hydro air sensor 306, 404 to monitor the hydro air in the hydro air or hot air cabinet 307, 405. In other words, the switch to monitoring mode will automatically bring in signals from the current sensors and hydro air sensors. If the boiler temperature or heating zone temperature deviates from the predetermined temperature programmed into the processor, the boiler sensor communicates to the processor. Furthermore, if the differential between the boiler temperature and the outside temperature exceeds the predetermined differential programmed, the sensors communicate with the processor. When the processor 4 receives the signal from the sensor, the processor signals the alarm relay 13, which sends an alarm notification to an alarm system 308, 410. Specifically, the processor 4 operates the alarm relay 13 located in the control board 1, 301, 401 to send an alarm notification to a central alarm 308, 410 or local/remote alarm 309, 411 by way of an alarm panel monitored by a central alarm station. This sequence of signals from the processor/control board to the alarm relay to an alarm system shall be referred to herein as the alarm pathway. Signals from a sensor or sensors to the processor feed into the alarm pathway. Also, as discussed in more detail herein, signals from a power failure relay can feed into the alarm pathway. The control board provides for the boiler to return to normal function when the outside temperature returns to a temperature above the predetermined temperature, e.g., in some cases above 40 degrees Fahrenheit. Specifically, when the ambient sensor sends a signal to the processor, the processor returns the boiler to normal function, which is known to those skilled in the art and includes operating without any alarm or alternate power and regular circulation of water when the enclosure needs to be heated. The processor may also return the boiler to high temperature or low water alarm only.
In other embodiments, the boiler protection apparatus prevents damage to the boiler and the enclosure to be heated by the boiler from damage due to cold temperatures by operating to circulate water through the heating system during a temperature detection event such as cold weather. In such an embodiment, the ambient sensor 305, 403 is a temperature sensor located outside the enclosure to be heated by the boiler. To perform this function, there is a boiler sensor 304, 402, 408 attached to the boiler or within the boiler and programmed to respond and communicate with the processor when the temperature of the boiler deviates from a predetermined temperature range. For example, the acceptable temperature range might be 33 degrees Fahrenheit to 40 degrees Fahrenheit. In addition, the ambient sensor is programmed to respond and communicate with the processor when the outside temperature drops below a predetermined temperature. That temperature would be selected from a range preferably between about 33 degrees Fahrenheit and about 40 degrees Fahrenheit, but could be above 40 degrees Fahrenheit or below 33 degrees Fahrenheit if desired. A temperature should be selected so the ambient sensor responds before the temperature drops low enough to cause the water in the heating system to freeze. This temperature can be adjusted. The sensors are also programmed to respond and signal to the processor when the boiler temperature and the outside temperature exceed a predetermined differential, see e.g., 408, the high temperature sensor. The differential may be plus or minus 5 degrees Fahrenheit, but may vary based on the needs of the user. The processor is programmed to operate circulation for circulating water. The circulation occurs in a zone or zones prone to freezing according to a predetermined circulation time. In some embodiments, the predetermined circulation time may be in the range of 1 to 5 minutes, but other circulation times may be used. Those skilled in the art will be able to determine appropriate intervals for circulating water.
Thus, when the outside temperature gets close to freezing and drops below the predetermined temperature programmed into the processor, the ambient sensor 305, 403 communicates the outside temperature to the processor 4 in the control board 1, 301, 401, and the control board switches from passive mode to monitoring mode. If the boiler temperature deviates from the predetermined temperature range programmed into the processor, the boiler sensor 304, 402, 408 communicates the boiler temperature to the processor, and the same switch occurs. Furthermore, if the differential between the boiler temperature and the outside temperature exceeds the predetermined differential programmed into the processor, the ambient sensor communicates with the processor. When the processor receives the signal from the sensor, the processor provides the circulation mode for circulating water. An interval timer is part of the processor and is set to turn on or off through a 4-pole double throw relay located in the control board connected to the circulator of the zone. Hot water then circulates through the heating system periodically to prevent freezing damage to the system. The circulation mode can be adjusted to provide circulating water at different time intervals, which may be 1 to 5 minutes or other time intervals known to those skilled in the art. When the temperature detection event ends, i.e., the ambient temperature rises above the predetermined low temperature range or drops below the predetermined high temperature, the processor provides for the zone to return to normal function. Specifically, when the ambient sensor sends a signal to the processor, the processor returns the boiler to normal function, which is known to those skilled in the art and includes operating without any alarm or alternate power and regular circulation of water when the enclosure needs to be heated. The processor may also return the boiler to high temperature or low water alarm only. Normal function specifically includes routine water circulation, i.e., circulation switches back to normal operation consistent with the room thermostat.
In another embodiment in which the apparatus prevents freezing damage, the ambient sensor could be located in a heating zone of a building to be heated by the boiler. The ambient sensor is programmed to respond and communicate with the processor when the ambient temperature of the heating zone drops below a predetermined temperature. That temperature would be selected from a range preferably between about 33 degrees Fahrenheit and about 40 degrees Fahrenheit, but could be above 40 degrees Fahrenheit or below 33 degrees Fahrenheit if desired. A temperature should be selected so the ambient sensor responds before the temperature drops low enough to cause the water in the heating system to freeze. The sensors also may be programmed to respond and signal to the processor when the differential between the boiler temperature and the outside temperature exceeds a predetermined differential. The differential may be plus or minus 5 degrees Fahrenheit, but may vary based on the needs of the user. In this embodiment, the processor can signal the alarm relay to send an alarm notification or the processor can provide circulation mode for circulating water through the heating zone.
In another embodiment in which the apparatus prevents freezing damage by responding to a temperature detection event, the apparatus functions with only a sensor attached to or within a boiler. The user programs the processor or control board so the boiler sensor 304, 402, 408 responds and communicates with the processor when the temperature of the boiler deviates from a predetermined temperature range. If the boiler temperature deviates from the predetermined temperature range programmed into the processor, the boiler sensor communicates the boiler temperature to the processor. When the processor receives the signal from the sensor, the processor initiates an alarm pathway.
It should be noted that, in some embodiments, the boiler sensor will constantly monitor for and respond to a temperature detection event. In these embodiments, the boiler sensor activity will occur even without a signal from the ambient sensor in response to an ambient temperature detection event. However, the switch from passive mode to monitoring mode caused by the signal from the ambient sensor can cause the control board and processor to start monitoring for certain heating system malfunctions, as explained in more detail herein.
An embodiment may have a third sensor that can also be a water flow or low water detector 409. In this embodiment, the apparatus can detect heating system malfunction by determining that the water level is low either in the boiler or in a heating zone. The third sensor is programmed to respond and send a signal to the processor if the water level in the boiler is low, the water level overheats due to high limit failure, or there is a heating zone water flow below a predetermined level. Most boilers have a low water shut off triggered by low water level. However, low water shut off in a boiler doesn't always work, and in an embodiment, the low water shut off is based on the temperature of sections 406, 407 of the boiler. Thus, if the temperature is too high because the boiler water drops below a pre-determined level, the water sensor communicates the boiler low water level to the processor. When the processor receives the signal from the sensor, the processor initiates an alarm pathway. As such, the owner or occupant of the enclosure to be heated by the boiler can take appropriate action to prevent further damage to the boiler.
In another embodiment, the boiler protection apparatus sounds an alarm in the event of power failure to the boiler. Control board 301, 401 is attached to the boiler power supply. The power failure relay may be attached to the boiler or located within the control board. In some embodiments, the power failure relay, shown in
An embodiment can also detect circulator failure by determining whether the boiler circulator is drawing too much or too little current (See
The overcurrent/undercurrent sensor may be connected to the hydro-air blower motor to monitor motor current and is programmed to respond and send a signal to the processor if it detects that the burner motor is drawing too much or too little current which deviates from a predetermined current draw set to motor FLA (full load amperage). Such deviation can indicate motor failure due to tight bearings, loss of drive belt or shaft shear. Thus, if the current draw deviates from the level programmed into the overcurrent/undercurrent sensor, the overcurrent/undercurrent sensor communicates with the processor, which signal may travel via a current relay in
An alternative embodiment, also shown in
Another embodiment can detect circulator failure by determining loss of circulator impeller, which is essentially a turbine that causes water flow. In this embodiment a hydro air sensor 306, 404 detects loss of a circulator impeller and initiates an alarm pathway. As such, the owner or occupant of the building to be heated by the boiler can have the impeller repaired or replaced immediately to prevent further damage to the boiler. In some embodiments, a current sensor may be used to detect undercurrent or a flow sensor may be used to detect when an impeller falls off. The processor may also provide a signal to circulate water through the zone to be heated. Any of the aforementioned embodiments regarding circulator failure can detect zone failure by determining circulator failure. If a person of skill in the art is notified of circulator failure, he can detect failure of a heating zone of the heating system being monitored.
An embodiment of the apparatus can also monitor temperature of the heating coils in the boiler by employing a hydro air sensor. This embodiment is shown in
Various embodiments provide methods of protecting a boiler from damage comprising some of the following functions. The foregoing description discusses some representative embodiments, and is not limiting. Other functions and embodiments will be apparent to those skilled in the art. These include detecting ambient temperature detection events, temperature detection events and heating system malfunction, including but not limited to situations where the temperature of the boiler deviates from a predetermined temperature range, when the temperature of heating coils in the boiler deviates from a predetermined temperature range, when ambient temperature drops below a predetermined temperature range, boiler failure, circulator failure and low water level in the boiler. These methods may be performed by embodiments that utilize components the same as or similar to those described above, including a control board, a processor, relays, sensors, alarms, etc., connected in similar arrangements. These methods will be described in more detail below.
One method of protecting a boiler from damage is to detect boiler failure and provide an alarm notification in the event of failure. This can include detecting power failure to the boiler and restoring power by providing it from an alternative power source. Such alternative power source could include a generator or a battery backup, or other power sources known to those skilled in the art. In some embodiments, boiler failure is detected by monitoring power via a power failure relay 12. The features of the power failure relay are discussed above in more detail, and it may be attached to the boiler 300, 400 and may consist of a 120-volt coil. When the power failure relay 12 detects power failure of the boiler 300, 400, it initiates an alarm pathway. As such, the owner or occupant of the enclosure to be heated by the boiler can take appropriate action to prevent further damage to the boiler. Alternatively, or in addition to initiating an alarm pathway, after the processor 4 communicates with the control board 1, 301, 401, the control board may then restore power to the boiler from an alternative power source, e.g., at battery backup 413. Boiler failure can also be detected by determining computer malfunction where a computer operates the boiler when boiler temperature drops below a predetermined temperature in relation to the outside temperature.
Another method performed by an embodiment is to detect circulator failure by determining whether the circulator is drawing too much or too little current, or when bearings are too tight, the motor fails, or when there is coupling or impeller loss. The appropriate current level varies depending on the size of the circulator motor. A person of ordinary skill in the art would set the appropriate current level based on the size of the motor, and if the level is too high or too low, a sensor will send a signal to the processor. This function can be performed by employing an overcurrent/undercurrent sensor 313, which monitors the current being drawn through the current transformers of the circulator motor or motors 310, 415. Alternatively, if the boiler is a motor-fired boiler, the too much or too little current is detected by monitoring boiler bearing function. When the bearings get too tight, the current level increases. In addition, there may be changes in current level in the burner motor. The overcurrent/undercurrent sensor is programmed to respond and send a signal to the processor if it detects that the circulator is drawing too much or too little current which deviates from a predetermined current draw set to motor FLA (full load amperage).
Thus, in this method, if the current draw deviates from the level programmed into the overcurrent/undercurrent sensor 313, the overcurrent/undercurrent sensor initiates an alarm pathway. As such, the owner or occupant of the enclosure to be heated by the boiler can take appropriate action to prevent further damage to the boiler. It should also be noted that circulator bearing failure can be detected by monitoring current to circulator in the same fashion. Further, an overcurrent or undercurrent sensor can be connected to the processor to detect motor undercurrent or overcurrent such as bearing failure, shaft or burner loss.
An alternative method is to detect circulator failure by a hydro air sensor 306, 404. The hydro air unit may be located in a hydro air blower cabinet 307, 405. The hydro air sensor is programmed to respond and send a signal to the processor if it detects low temperature in the cabinet which deviates from a predetermined air temperature level. Thus, if the hydro air sensor detects that the air flow has deviated from the predetermined air flow level, the hydro air sensor initiates an alarm pathway. As such, the owner or occupant of the enclosure to be heated by the boiler can take appropriate action to prevent further damage to the boiler and heating system.
Another method is to detect circulator failure by determining loss of a circulator impeller and initiate an alarm pathway or to circulate water through the system when there is no water flow or low current. When the hydro air sensor determines loss of a circulator impeller it initiates an alarm pathway. As such, the owner or occupant of the enclosure to be heated by the boiler can have the impeller repaired or replaced immediately to prevent further damage to the boiler. In some embodiments, a current sensor may be used to detect undercurrent or a flow sensor may be used to detect when an impeller falls off.
An embodiment includes a method of protecting a hydro air coil from freezing due to low cabinet temperature or enclosure temperature. A hydro air coil is a cabinet in which air is blown over a radiator or convector. The cabinet may be located near the boiler or in an attic or elsewhere in an enclosure to be heated by the heating system, and the enclosure generally holds the radiator. In an embodiment, this method is done by using an air sensor to detect low temperature in the cabinet. The air sensor may be located in an air blower cabinet. When the sensor detects an ambient temperature detection event in the cabinet or enclosure, it initiates an alarm pathway. As such, the owner or occupant of the enclosure to be heated by the boiler can take appropriate steps to prevent further damage to the boiler and heating system.
Another method of protecting the boiler is to monitor the relay power of heating system circulators through a power relay connected to circulator power supply. Connection to the power supplying another manufacturer's relay or relay board will open power to the alarm relay located in the control board 301, 401. Contacts will close, and the signal from the relay initiates an alarm pathway. As such, the owner or occupant of the enclosure to be heated by the boiler can take appropriate action to prevent further damage to the boiler.
In some embodiments, the method of preventing damage to the boiler and the enclosure to be heated by the boiler is to prevent damage from freezing water due to cold weather by detecting an ambient temperature detection event or a temperature detection event and providing an alarm notification. In such an embodiment, the ambient sensor 305, 403 is a temperature sensor located outside the building to be heated by the boiler. In this method, a sensor is attached to the boiler and is programmed to respond and communicate with the processor when the temperature of the boiler deviates from a predetermined temperature range. In some embodiments the temperature range will be 33 to 40 degrees Fahrenheit, but other temperature ranges may be used. If the boiler is a steam boiler 400, the boiler sensor 408 may be located in the jacket of the steam boiler or in the water of the steam boiler. In addition, the ambient sensor is programmed to respond and communicate with the processor when the outside temperature drops below a predetermined temperature. That temperature would be selected from a range preferably between about 33 degrees Fahrenheit and about 40 degrees Fahrenheit, but could be above 40 degrees Fahrenheit or below 33 degrees Fahrenheit if desired. A temperature should be selected so the ambient sensor responds before the temperature drops low enough to cause the water in the heating system to freeze. The sensors are also programmed to respond and signal to the processor when the differential between the boiler temperature and the outside temperature exceeds a predetermined differential. The differential may be plus or minus 5 degrees Fahrenheit.
Thus, in this method, when there is an ambient temperature detection event such that the outside temperature gets close to freezing and drops below the predetermined temperature programmed into the processor, the ambient sensor 305, 403 communicates the outside temperature to the processor 4. If the boiler temperature deviates from the predetermined temperature range programmed into the processor 4, the boiler sensor 304, 402, 408 communicates the boiler temperature to the processor. Furthermore, if the differential between the boiler temperature and the outside temperature exceeds the predetermined differential programmed into the boiler sensor 304, 402, 408 and ambient sensor 305, the boiler sensor 304, 402, 408 or ambient sensor 305 communicates with the processor 4. The communication may be by voltage fluctuations from the J sensor to the processor. One or more J sensors may be inserted into a section or sections of the boiler. The processor in some embodiments of this method will be a ZEN Controller. When the processor receives the signal from the sensor, the processor in turn communicates with the control board 1, 301, 401, which communicates with the alarm relay 13, which sends an alarm notification to an alarm system 308. Specifically, the processor operates the alarm relay 13 located in the master control board 1, 301, 401 to initiate an alarm pathway. In an embodiment, a set of contacts is connected to a monitoring alarm control panel. When the contacts open, a zone is triggered and a signal is sent by land line or radio to a central station. The control board provides for the boiler to return to normal function when the outside temperature returns to a temperature above the predetermined temperature, e.g., in some cases above 40 degrees Fahrenheit. Specifically, when the ambient sensor sends a signal to the processor, the processor returns the boiler to normal operation. The processor may also return the boiler to high temperature or low water alarm only.
In other embodiments, the method of protecting a boiler from damage is to circulate water through the heating system when an ambient temperature detection event occurs. In such an embodiment, the ambient sensor 305, 403 is a temperature sensor located outside the enclosure to be heated by the boiler. To perform this function, a sensor 304, 402 is attached to the boiler 300, 400 and is programmed to respond and communicate with the processor 4 when the temperature of the boiler deviates from a predetermined temperature range. In some embodiments, the temperature range may be 40 to 50 degrees Fahrenheit, but other temperature ranges may be used. In addition, the ambient sensor 305, 403 is programmed to respond and communicate with the processor 4 when the outside temperature drops below a predetermined temperature. That temperature would be selected from a range preferably between about 33 degrees Fahrenheit and about 40 degrees Fahrenheit, but could be above 40 degrees Fahrenheit or below 33 degrees Fahrenheit if desired. The goal is to select a temperature so the ambient sensor responds before the temperature drops low enough to cause the water in the heating system to freeze. The sensors are also programmed to respond and signal to the processor when the differential between the boiler temperature and the outside temperature exceeds a predetermined differential. Temperature differentials may be 5 to 10 degrees Fahrenheit, but other temperature differentials may be used. In some embodiments, the processor is programmed to operate circulation mode for circulating water. The processor will turn the circulator on for a predetermined period of time, which may be about 1 to about 5 minutes, but other times may be used. Those skilled in the art will be able to determine appropriate intervals for circulating water.
Thus, in this method, when the outside temperature gets close to freezing and drops below the predetermined temperature programmed into the ambient sensor 305, 403, the ambient sensor communicates the outside temperature to the processor 4. Such signals from the ambient sensor turn the control board 1, 301, 401 from a passive mode to a monitoring mode. Passive mode is essentially a stand-by position, which includes monitoring of boiler temperature, but does not include monitoring of circulators or hydro air. When the control board 1, 301, 401 is in this monitoring mode, the processor 4 then signals the boiler sensor 304, 402, 408 or an ambient sensor 305, 403 in a heating zone to monitor the temperature of the boiler or the heating zone or to monitor the circulators and hydro air. In other words, the switch to monitoring mode will automatically bring in signals from the current sensors and hydro air sensors. If the boiler temperature deviates from the predetermined temperature range programmed into the processor, the boiler sensor communicates the boiler temperature to the processor. Furthermore, if the differential between the boiler temperature and the outside temperature exceeds the predetermined differential programmed into the processor, the processor shows circulation function and turns on the circulator for a predetermined time.
In addition, in this method, there is a third boiler sensor, which is a low water sensor 409 which communicates with the processor. When the processor receives the signal from the low water sensor, the processor provides the circulation mode for circulating water through a time interval programmed into the processor. An interval timer is part of the processor set to turn on or off through a 4-pole double throw relay located in the control board connected to the circulator of the zone. Hot water then circulates through the heating system periodically to prevent freezing damage to the system. The circulation mode can be adjusted to provide circulating water at different time intervals known to those skilled in the art. The boiler can also be switched to maintain a 120 degree Fahrenheit temperature during cold weather to prevent shocking the boiler from too low water temperature return differential.
In another embodiment where this method is to prevent freezing damage, the ambient sensor 305, 403 could be located in a heating zone of a building to be heated by the boiler. The ambient sensor 305, 403 is programmed to respond and communicate with the processor 4 when the ambient temperature of the heating zone drops below a predetermined temperature. That temperature would be selected from a range preferably between about 33 degrees Fahrenheit and about 40 degrees Fahrenheit, but could be above 40 degrees Fahrenheit or below 33 degrees Fahrenheit if desired. In this method, a temperature should be selected so the ambient sensor responds before the temperature drops low enough to cause the water in the heating system to freeze. The sensors are also programmed to respond and signal to the processor when the boiler temperature and the outside temperature exceeds a predetermined setting. In some embodiments, the differential may be plus or minus 5 degrees Fahrenheit, but it may vary based on the needs of the user. In this method, the processor 4 can signal the alarm relay 13 to send an alarm notification or the processor can provide circulation mode for circulating water through the heating zone.
In another embodiment in which the method is to prevent freezing damage, there could be only a boiler sensor attached to boiler and no additional sensors. In this method, the boiler sensor 304, 402, 408 is programmed to respond and communicate with the processor when the temperature of the boiler deviates from a predetermined temperature range. If the boiler temperature deviates from the predetermined temperature range programmed into the processor, the boiler sensor initiates an alarm pathway.
In some embodiments, there is a third boiler sensor that can also be a low water flow sensor 409. In such embodiments, the method is to detect possible boiler failure or malfunction by determining that the water level is low either in the boiler or in a heating zone. In this method, the processor 4 is programmed so the third boiler/low water flow sensor 409 will respond and send a signal to the processor if the water level in the boiler or in a heating zone drops below a predetermined level, i.e., when the water level is below the water level sensor. Most boilers have a low water shut off triggered by low water level. However, low water shut off in boiler doesn't always work, and in an embodiment, the low water shut off is based on the temperature of sections of the boiler. Thus, if the temperature is too high because the boiler water drops below a pre-determined level, the third sensor communicates the boiler low water level to the processor, initiating an alarm pathway. As such, the owner or occupant of the building to be heated by the boiler can take appropriate action to prevent further damage to the boiler.
Alternatively, a method of protecting a boiler from damage could include the situation where detection of ambient temperature below a predetermined temperature causes monitoring of boiler temperature. To perform this method, the boiler sensor 304, 402 is attached to the boiler 300, 400. If the boiler is a steam boiler, the boiler sensor 408 may be located in the jacket of the steam boiler or in the water of the steam boiler. There is an ambient temperature sensor 305, 403 located either outside the building to be heated by the boiler or in a heating zone of the building to be heated by the boiler. The ambient sensor is programmed to respond and communicate with the processor 4 when the outside temperature drops below a predetermined temperature. That temperature would be selected from a range preferably between about 33 degrees Fahrenheit and about 40 degrees Fahrenheit, but could be above 40 degrees Fahrenheit or below 33 degrees Fahrenheit if desired. A temperature should be selected so the ambient sensor responds before the temperature drops low enough to cause the water in the heating system to freeze. When the outside temperature or temperature in the heating zone drops below a predetermined temperature, the ambient sensor sends a signal to the processor, either initiating an alarm pathway or providing circulation mode for circulating water.
Other methods can be accomplished using various embodiments. One method includes detecting circulator failure by determining loss of circulator impeller using an air sensor and circulating water through the zone to be heated. Another method is monitoring temperature of the boiler heating coils and triggering the alarm pathway if the heating coil temperature deviates from a predetermined range known to those skilled in the art.
The examples provided herein are representative of preferred embodiments, are exemplary, and are not intended as limitations on the scope of the invention. It will be readily apparent to a person skilled in the art that varying substitutions and modifications may be made to the invention disclosed herein without departing from the scope and spirit of the invention. The invention illustratively described herein suitably may be practiced in the absence of any element or elements, limitation or limitations which are not specifically disclosed herein. Thus, for example, in each instance herein any of the terms “comprising”, “consisting essentially of” and “consisting of” may be replaced with either of the other two terms. The terms and expressions which have been employed are used as terms of description and not of limitation, and there is no intention that in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the invention claimed. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims.
The processor, sensor, control board, relay and alarm arrangement discussed herein is merely exemplary and illustrative of apparatus and methods using inexpensive and readily-available components and hardware, and the illustrated examples are not limiting. Those skilled in the art will recognize various alternatives and options, including systems and setups that may involve one or more different types of processors, relays, control boards, connectors, cables, routers, hubs, sensors, etc., as well as setups that use other types of communication interfaces and/or controls, including interfaces and/or controls that may be more sophisticated and that can offer additional options.
Other embodiments are set forth within the following claims.
