Patent Application
20070243495
This invention generally relates to gaseous fuel burning appliances and, more particularly, to calibration of gas control valves based on a type of gaseous fuel controlled thereby.
When installing a gas operated appliance, a tradesperson is, at times, expected to perform a variety of tasks. For example, the tradesperson may be required to calibrate each valve in the appliance to correspond to the type of gas used by the consumer (e.g., natural gas, liquefied petroleum gas, etc.). In addition, the tradesperson may also have to adjust each valve in the appliance to accommodate line pressure changes from the source supply. Making these adjustments can take considerable time and effort.
In addition to the above, the tradesperson may have to change the jets that have been installed in the appliance at the manufacturer's site. Because the jets are generally made to properly operate with a particular type of gas, the type of jets in the appliance should match the type of gas that the consumer is planning on using. If this is not the case, the tradesperson has the added task of swapping out the jets in the appliance. Making these alterations can take considerable time and effort.
Unfortunately, if a tradesperson has to make field calibrations, adjust for line pressure changes, and replace jets, the cost of the installation and/or servicing of the appliances is greatly increased. There exists, therefore, a need in the art for an apparatus for, and a method of, calibrating a valve, adjusting for pressure changes, and accommodating different jets for the type of gaseous fuel used at an installation location without requiring a tradesperson to physically perform the tedious and time consuming tasks. These and other advantages of the invention, as well as additional inventive features, will be apparent from the description of the invention provided herein.
The system and method of the present invention allows electronic calibration of the valve for the type of Gas, Line-Pressure, Jet and Burner Configuration (GLPJ&BC) to be used in an appliance (in relation to the valve/metering device only) without the need to have a tradesperson manually adjusting on site.
In one embodiment, an electronic gas control apparatus is provided. The apparatus includes a variable flow valve, an igniter, a flame sensor, and an electronic controller. The variable flow valve has a flow range that equals or exceeds a required flow range for each gas suitably combusted by the burner in the appliance. The igniter is disposed proximate the burner and configured to ignite the gas dispensed by the burner to produce a flame. The flame sensor is disposed proximate the burner and configured to monitor for a presence of the flame. The electronic controller is operably coupled to each of the variable flow valve, the igniter, and the flame sensor, and is configured to control the position of the variable flow valve, to activate the igniter, to receive a flame status signal from the flame sensor, and to vary the position of the variable flow valve until a flame is sensed. The controller then adjusts or calibrates its variable flow valve control algorithm based on the initial position when the flame status signal indicates a flame at the burner. As such, the electronic controller is calibrated for the GLPJ&BC being used.
In another embodiment, a method of calibrating the controller of a variable flow valve is provided. The method includes sending an ignition signal and varying a position of the variable flow valve until receiving an ignition status signal. The method further includes recognizing a valve position if the ignition status signal indicates a flame and sending a valve position signal if the ignition status signal indicates ignition failure.
Other aspects, objectives and advantages of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:
While the invention will be described in connection with certain preferred embodiments, there is no intent to limit it to those embodiments. On the contrary, the intent is to cover all alternatives, modifications and equivalents as included within the spirit and scope of the invention as defined by the appended claims.
Referring to
The variable flow valve 12 defines an inlet 20 and an outlet 22. The inlet 20 is operably coupled to a fuel supply 24 while the outlet 22 is operably coupled to a burner 26. In the illustrated embodiment, the valve 12 is coupled to fuel supply that distributes a gaseous fuel. Therefore, for the purposes of illustration and ease of reading, in the paragraphs below the fuel may be referred to as a gas.
In order to meter out various flow rates of gas or restrict the flow of gas altogether, the valve 12 is able to assume a variety of different positions. In one embodiment, the valve 12 has eighteen metering positions where gas is dispensed from the valve at various rates, although one skilled in the art will recognize from this description that more or fewer metering positions may be used. The valve 12 also has one “off” position where gas is prevented from being metered out.
The variable flow valve 12 in the illustrated embodiment suitably receives and dispenses a variety of different gases (e.g., natural gas, liquefied petroleum gas, propane etc.). In order to provide proper heating and functionality of the appliance regardless of the type of gas used by the consumer, the valve 12 is designed to have a flow range that equals or exceeds the maximum flow range for any one type of gas that may be used in the apparatus 10 and/or combusted by the burner 20.
In one embodiment, the valve 12 is a variable flow valve such as that disclosed in U.S. Pub. Pat. Appln. 2006/0278285 entitled “Variable Flow Valve,” the teachings and disclosure of which are hereby incorporated in their entireties by reference thereto. In another embodiment, the valve 12 is a variable flow valve as disclosed in patent application Ser. No. 11/736,199 entitled “Power Saving Locking Coil” filed on Apr. 17, 2007, the teachings and disclosure of which are hereby incorporated in their entireties by reference thereto.
The valve 12 is operably coupled to and controlled by the controller 18. In the illustrated embodiment of
As shown in
The flame sensor 16 is disposed proximate the burner 26 and positioned to sense the flame 28. The flame sensor 16 is operably coupled to the controller 18 so that the controller 18 can determine when a flame is present. In the illustrated embodiment of
As noted above, the electronic controller 18 is operably coupled to each of the valve 12, the igniter 14, and the flame sensor 16. Therefore, the electronic controller 18 is able to control the flow of gaseous fuel from the gas flow supply 24 to the burner 26. Although not shown, the controller 18 may contain numerous typical electronic components and systems such as, for example, a microprocessor or microcontroller, inputs and outputs, transmitting and receiving equipment, peripheral attachment connectors, and the like.
By using the valve 12 in conjunction with the flame sensor 16 and the electronic igniter 14, it becomes possible for the controller 18 to determine at what position inside the multi-position valve 12 when the gas will, and will not, ignite for any particular Gas, Line-Pressure, Jet and Burner Configuration (GLPJ&BC). This electronic sensing when the flame 28 is, or is not, present allows the controller 18 to calibrate itself on start-up for any particular set-up. This activity can be done on installation and/or during a recalibration reset stage if so required.
The electronic controller 18 is also operably coupled to a power supply and a user interface. As shown in
Among being able to perform a host of other functions, the electronic controller 18 is configured to activate the igniter 14, to receive a flame status signal from the flame sensor 16, to control the position of the valve 12, and to recognize a position of the variable flow valve 12 when the flame status signal indicates a flame 28 at the burner 26. Therefore, as will be more fully explained below, the controller 18 uses the variable flow valve 12 to calibrate its settings for the particular GLPJ&BC being used at its particular consumer location.
In one embodiment, the electronic controller 18 includes a memory 30. The memory 30 is used by the controller 18 in one embodiment to store, at least temporarily, information regarding the valve 12 and its positions. Information regarding the igniter 14, the flame sensor 16, and the controller 18 itself may also be stored in the memory 30.
The electronic controller 18 may be configured with a logic based software program, program logic, etc. that allows the controller 18 to perform a calibration operation to properly configure the operating parameters of the appliance based on the GLPJ&BC at the consumer location. Specifically, the controller 18 at start up calibration will adjust the valve 12 to allow an amount of gaseous fuel flow to the burner 26. The controller 18 will control the igniter 14 to attempt to ignite the gaseous fluid flowing to the burner 26. Once the flame sensor 16 detects that a flame is present, the controller 18 adjusts its control algorithms to properly control the flow of the gaseous fuel via the valve 12 for the particular installation based on the position of the valve 12 at initial ignition, regardless of the particular Gas, Line-Pressure, Jet and Burner Configuration (GLPJ&BC).
In one embodiment, in operation the controller 18 sends an initial valve position signal to the valve 12. As such, gas from the gas supply 24 is released through the valve 12 to the burner 26. Thereafter, the controller 18 sends an ignition signal to the igniter 14. The flame sensor 16 then operates to confirm the presence or absence of the flame 28 at the burner 26. After monitoring for the flame 28, the flame sensor 16 sends an ignition status signal that is received by the controller 18.
If the flame status signal indicates that the flame 28 is present, the controller 18 utilizes this valve position as the initial or minimum setting for controlling the burner flame. If desired, the valve position and a flame status indicator is stored in memory, transmitted to the user interface or elsewhere, displayed on the user interface or elsewhere, or otherwise utilized. The controller 18 can also inform a user through, for example, the user interface if the flame is present or not.
If the flame status signal indicates that the flame 28 is absent, i.e. there has been an ignition failure, the controller 18 adjusts the valve position signal to the valve 12 to increase the flow of gas therethrough. This is continued until a flame is detected. Once detected, the controller 18 uses this valve position as the minimum setting for control of the appliance.
Each of the above steps may be performed during an initial installation or during a recalibration process. Also, if pressure changes occur in the fuel supply 24, using the above method the controller 18 is able to adjust the position of the valve 12 accordingly. Initiation of such a recalibration process may be effectuated via the user interface.
From the foregoing, those skilled in the art will recognize that the apparatus 10 and method of using the same permits field calibration and proper usage of an appliance at an installation location regardless of the GLPJ&BC, without requiring a tradesperson to physically perform the tedious and time consuming tasks. Thus, the apparatus 10 and the use thereof saves time and money.
All references, including publications, patent applications, and patents cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) is to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.
Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Variations of those preferred embodiments may become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventors expect skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than as specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
This patent application claims the benefit of U.S. Provisional Patent Application No. 60/792,775, filed Apr. 18, 2006, the teachings and disclosure of which are hereby incorporated in their entireties by reference thereto.
| Number | Date | Country | |
|---|---|---|---|
| 60792775 | Apr 2006 | US |
