US20110277706A1 - Gas-fired heating device having a thermopile - Google Patents
Gas-fired heating device having a thermopile Download PDFInfo
- Publication number
- US20110277706A1 US20110277706A1 US12/779,078 US77907810A US2011277706A1 US 20110277706 A1 US20110277706 A1 US 20110277706A1 US 77907810 A US77907810 A US 77907810A US 2011277706 A1 US2011277706 A1 US 2011277706A1
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- United States
- Prior art keywords
- thermopile
- pilot
- water heater
- controller
- gas valve
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- Abandoned
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- 230000004044 response Effects 0.000 claims abstract description 10
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- 230000002159 abnormal effect Effects 0.000 claims description 8
- 238000000034 method Methods 0.000 claims description 6
- 239000000428 dust Substances 0.000 claims description 5
- 238000013021 overheating Methods 0.000 claims description 2
- 238000009423 ventilation Methods 0.000 claims description 2
- 238000001514 detection method Methods 0.000 claims 2
- 238000012544 monitoring process Methods 0.000 claims 1
- 238000002485 combustion reaction Methods 0.000 description 20
- 239000000446 fuel Substances 0.000 description 12
- 238000010276 construction Methods 0.000 description 9
- 238000007789 sealing Methods 0.000 description 4
- 238000009413 insulation Methods 0.000 description 3
- 230000009471 action Effects 0.000 description 2
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- 230000008569 process Effects 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 230000000153 supplemental effect Effects 0.000 description 1
Images
Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H1/00—Water heaters, e.g. boilers, continuous-flow heaters or water-storage heaters
- F24H1/18—Water-storage heaters
- F24H1/20—Water-storage heaters with immersed heating elements, e.g. electric elements or furnace tubes
- F24H1/205—Water-storage heaters with immersed heating elements, e.g. electric elements or furnace tubes with furnace tubes
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24D—DOMESTIC- OR SPACE-HEATING SYSTEMS, e.g. CENTRAL HEATING SYSTEMS; DOMESTIC HOT-WATER SUPPLY SYSTEMS; ELEMENTS OR COMPONENTS THEREFOR
- F24D18/00—Small-scale combined heat and power [CHP] generation systems specially adapted for domestic heating, space heating or domestic hot-water supply
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/10—Control of fluid heaters characterised by the purpose of the control
- F24H15/112—Preventing or detecting blocked flues
- F24H15/116—Disabling the heating means in response thereto
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/10—Control of fluid heaters characterised by the purpose of the control
- F24H15/128—Preventing overheating
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/10—Control of fluid heaters characterised by the purpose of the control
- F24H15/174—Supplying heated water with desired temperature or desired range of temperature
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/20—Control of fluid heaters characterised by control inputs
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/20—Control of fluid heaters characterised by control inputs
- F24H15/212—Temperature of the water
- F24H15/223—Temperature of the water in the water storage tank
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/30—Control of fluid heaters characterised by control outputs; characterised by the components to be controlled
- F24H15/305—Control of valves
- F24H15/31—Control of valves of valves having only one inlet port and one outlet port, e.g. flow rate regulating valves
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/30—Control of fluid heaters characterised by control outputs; characterised by the components to be controlled
- F24H15/355—Control of heat-generating means in heaters
- F24H15/36—Control of heat-generating means in heaters of burners
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/30—Control of fluid heaters characterised by control outputs; characterised by the components to be controlled
- F24H15/395—Information to users, e.g. alarms
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/40—Control of fluid heaters characterised by the type of controllers
- F24H15/414—Control of fluid heaters characterised by the type of controllers using electronic processing, e.g. computer-based
- F24H15/421—Control of fluid heaters characterised by the type of controllers using electronic processing, e.g. computer-based using pre-stored data
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H9/00—Details
- F24H9/20—Arrangement or mounting of control or safety devices
- F24H9/2007—Arrangement or mounting of control or safety devices for water heaters
- F24H9/2035—Arrangement or mounting of control or safety devices for water heaters using fluid fuel
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24D—DOMESTIC- OR SPACE-HEATING SYSTEMS, e.g. CENTRAL HEATING SYSTEMS; DOMESTIC HOT-WATER SUPPLY SYSTEMS; ELEMENTS OR COMPONENTS THEREFOR
- F24D2101/00—Electric generators of small-scale CHP systems
- F24D2101/60—Thermoelectric generators, e.g. Peltier or Seebeck elements
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24D—DOMESTIC- OR SPACE-HEATING SYSTEMS, e.g. CENTRAL HEATING SYSTEMS; DOMESTIC HOT-WATER SUPPLY SYSTEMS; ELEMENTS OR COMPONENTS THEREFOR
- F24D2103/00—Thermal aspects of small-scale CHP systems
- F24D2103/10—Small-scale CHP systems characterised by their heat recovery units
- F24D2103/17—Storage tanks
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H15/00—Control of fluid heaters
- F24H15/10—Control of fluid heaters characterised by the purpose of the control
- F24H15/104—Inspection; Diagnosis; Trial operation
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F24—HEATING; RANGES; VENTILATING
- F24H—FLUID HEATERS, e.g. WATER OR AIR HEATERS, HAVING HEAT-GENERATING MEANS, e.g. HEAT PUMPS, IN GENERAL
- F24H2240/00—Fluid heaters having electrical generators
- F24H2240/08—Fluid heaters having electrical generators with peltier elements
Definitions
- the present invention relates to heating devices, and particularly, to gas heating devices. More particularly, the invention relates to a controller used for controlling gas heating devices.
- An exemplary gas-fired heating device is a gas water heater having a burner.
- Gas water heaters often include a combustion chamber and an air plenum disposed below a tank, such as a water tank.
- a gas manifold tube, an ignition source, a thermocouple, and a pilot tube typically extend into the combustion chamber.
- fuel is introduced into the combustion chamber through the gas manifold tube and a burner element. This fuel is ignited by a pilot burner flame or the ignition source, and the flame is maintained around the burner element.
- Air is drawn into the plenum via an air inlet, and mixes with the fuel to support combustion within the combustion chamber.
- the products of combustion typically flow through a flue or heat exchange tube in the water tank to heat the water by conduction.
- the invention provides a new gas water heater having a burner, a pilot, a gas valve coupled to the pilot, a thermopile thermally coupled to the pilot flame and operable to generate an output voltage, and a controller powered by the thermopile and coupled to the gas valve.
- the controller is operable to control the gas valve based on the output voltage it receives from the thermopile.
- the controller includes a processor that processes a voltage value received by the controller and communicates a shutdown signal for preventing gas flow to the pilot and/or burner when an insufficient amount of voltage is outputted by the thermopile.
- the invention provides a controller for a gas water heater.
- the gas water heater includes a burner, a pilot, an igniter, an electrically controlled gas valve, and a thermopile.
- the thermopile can be positioned in a standing pilot flame provided by the pilot.
- the standing pilot flame causes the thermopile to generate an output voltage that it used to power the controller and the electrically controlled gas valve.
- the controller responds to an insufficient amount of output voltage provided by the thermopile by, for example, closing the electrically controlled gas valve.
- the insufficient amount of output voltage can indicate the presence of a possible flammable vapor event or a possible lint, dust, or oil blockage event.
- the invention provides a method of controlling a gas water heater.
- the gas water heater includes a burner, a pilot, an igniter, a thermopile, a controller, and a gas valve.
- the method can include detecting a possible flammable vapor event or a possible lint, dust, or oil blockage event.
- the thermopile produces an output voltage in response to a standing pilot flame generated by the pilot and igniter.
- the output voltage generated by the standing pilot flame can be between about 400 and 800 millivolts.
- the controller When the thermopile outputs an insufficient amount of voltage, a voltage less than 400 millivolts, for example, the controller generates a shutdown signal and closes the gas valve.
- the controller when the thermopile outputs too much voltage, a voltage greater than 800 millivolts, for example, the controller generates the shutdown signal and closes the gas valve. The closing of the gas valve prevents gas flow to the pilot and burner, thereby preventing any combustion from occurring.
- FIG. 1 is a perspective view of a gas water heater.
- FIG. 2 is a sectional view of the bottom portion of the gas water heater.
- FIG. 3 is a block diagram of a portion of the gas water heater.
- FIGS. 1 and 2 illustrate a storage-type, gas-fired water heater 10 that includes a base pan 15 .
- the base pan 15 may be constructed of stamped metal or molded plastic, for example, and includes a generally horizontal bottom wall 20 , a vertical rise 25 having an air inlet opening 27 , and an elevated step 30 .
- the water heater 10 also includes a water tank 35 , insulation 40 surrounding the tank 35 , and an outer jacket 45 surrounding the insulation 40 and the water tank 35 .
- a skirt 50 is supported by the base pan's elevated step 30 and in turn supports the water tank 35 .
- the elevated step 30 also supports the insulation 40 and jacket 45 .
- the elevated step 30 supports a divider 60 that divides the space between the bottom of the tank 35 , skirt 50 , and the base pan 15 into a combustion chamber 65 (above the divider 60 ) and plenum 70 (below the divider 60 ).
- a cold water inlet tube 75 and a hot water outlet tube 80 extend through a top wall of the water tank 35 .
- a flue 85 extends through the tank 35 , and water in the tank 35 surrounds the flue 85 .
- the flue 85 includes an inlet end 90 and an outlet end 95 .
- the combustion chamber 65 and plenum 70 space are substantially air-tightly sealed, except for the air inlet opening 27 and inlet end 90 of the flue 85 .
- Seals 105 between the skirt 50 and the tank 35 and base pan 15 assist in sealing the space.
- the seals 105 may be, for example and without limitation, fiberglass material or a high-temperature caulk material.
- a radiation shield 110 sits on the divider 60 within the sealed combustion chamber 65 and reflects radiant heat up toward the tank 35 .
- a flame arrester 115 is affixed in a sealed condition across an opening 120 in the divider 60 such that all air flowing from the plenum 70 into the combustion chamber 65 should flow through the flame arrester 115 .
- the air inlet 27 , air plenum 70 , and opening 120 in the divider 60 together define an air intake for the combustion chamber 65 , and air flowing into the combustion chamber 65 through the opening (see arrows in FIG. 2 ) 120 should flow through this air intake and the flame arrester 115 .
- the position and orientation of the flame arrester 115 are not limited to those shown in the drawings, and that substantially any construction will work provided that the flame arrester 115 acts as the gateway for the air flowing into the combustion chamber 65 from the plenum 70 .
- Sealing members 125 seal the periphery of the flame arrester 115 to the divider 60 to reduce the likelihood of air circumventing the flame arrester 115 .
- a single sealing member 125 may be used to seal the flame arrester 115 with respect to the divider 60 , or if the flame arrester fits snugly against the divider 60 , no sealing members 125 may be needed.
- the flame arrester 115 prevents flame within the combustion chamber 65 from igniting flammable vapors outside of the combustion chamber 65 .
- the air inlet 27 is covered by a lint, dust, and oil (“LDO”) filter 130 mounted to the outer surface of the base pan 15 .
- LDO filter 130 filters air flowing into the plenum 70 and reduces the likelihood that the flame arrester 115 will become occluded by lint or other debris.
- a burner 155 in the combustion chamber 65 burns a mixture of fuel and air to create the products of combustion that flow up through the flue 85 to heat the water in the tank 35 .
- the burner 155 receives fuel through a gas manifold 160 that extends in a sealed condition through an access door 165 mounted in a sealed condition over an access opening in the skirt 50 .
- non-powered refers to a device that is not powered from electrical mains. However, it is envisioned that the assembly 170 can be connected to electrical mains.
- a gas main 175 provides fuel to the input side of the assembly 170 .
- the assembly 170 includes a controller 200 ( FIG. 3 ) and a water temperature probe 180 that is threaded into the tank side wall 35 .
- Connected to the output side of the assembly 170 are the gas manifold 160 , a pilot burner 185 , a thermopile 190 , and an igniter 195 .
- the pilot burner 185 , thermopile 190 , and igniter 195 extend into the combustion chamber 65 in a sealed condition through a grommet in the access door 165 .
- the assembly 170 provides a flow of fuel to the pilot 185 to maintain a standing pilot burner flame, and this construction is therefore generally referred to as a “continuous pilot ignition” system.
- the igniter 195 is used to initiate the flame on the pilot 185 without having to reach into the combustion chamber with a match. A spark is generated by the igniter 195 in response to pushing a button on the assembly 170 .
- the thermopile 190 provides feedback to the assembly 170 and controller 200 as to the presence of flame at the pilot 185 .
- An exemplary thermopile 190 is a model Q313 thermopile generator manufactured by Honeywell.
- the assembly 170 permits fuel to flow to the burner 155 in response to a water temperature sensor (e.g., the water temperature probe 180 ) indicating that the water temperature in the water tank 35 has fallen below a selected temperature.
- a water temperature sensor e.g., the water temperature probe 180
- the assembly 170 shuts off fuel flow to the burner 155 , and the water heater 10 is in “standby mode” until the water temperature again drops to the point where the assembly 170 should again provide fuel to the burner 155 .
- An electrically controlled gas valve 205 ( FIG. 3 ), or more specifically, an electronically controlled gas valve is biased in the closed position with respect to the gas manifold 160 and the pilot 185 .
- the controller 200 stores some energy in a storage device 200 that allows for the gas valve 205 to be opened while igniting the pilot flame.
- the start up requires a user to actuate the push button of the assembly 170 which in turn opens the gas valve 205 and triggers the igniter 195 .
- the igniter 195 provides a spark to the pilot 185 while gas is flowing and establishes the pilot flame.
- the thermopile 190 is positioned near or within the pilot flame and produces an output voltage in response to the pilot flame.
- the output voltage is used as a power source by the controller 200 , which keeps the electrically controlled gas valve 205 open for the pilot flame 190 .
- An exemplary electrically controlled gas valve 205 that can be used with the invention is a model WV8840B gas valve, manufactured by Honeywell. Before proceeding further, the gas valve 205 is shown in FIG. 3 as a single device providing fuel to both the burner 185 and the pilot 190 . It should be understood, however, that the gas valve 205 can include multiple valves that are individually controlled.
- the assembly 170 is shown in FIG. 3 as including the controller 200 .
- the controller 200 receives a power from the thermopile 190 , the power having a plurality of components (e.g., a voltage, a current).
- the thermopile 190 provides a normal operation (or nominal) voltage of 400 to 800 millivolts to operate and control the assembly 170 .
- the output voltage is recognized as being in an insufficient output voltage (state) by the controller 200 if the output voltage is not within this range. For example, if the voltage is greater than 800 millivolts, then the pilot flame may be burning too hot indicating a first potential issue. Similarly, if the voltage is less than 400 millivolts, the pilot flame may be burning too cool indicating a second potential issue.
- the controller 200 issues a flag or signal after the output voltage traverses a first threshold voltage (e.g., about 400 millivolts).
- the signal can be provided to an output device (e.g., a light emitting diode, a display, an audible alarm, etc.) of the assembly 170 .
- the controller 200 can close the gas valve 205 , thereby deactivating the gas water heater 10 , after the output voltage provided by the thermopile 190 traverses a second threshold voltage (e.g., about 300 millivolts).
- the gas valve 205 closes in response to a signal (e.g., the application or removal of a voltage, an instruction, etc.) being sent from the controller 200 to the gas valve 205 .
- the controller 200 includes a processor 220 and memory 225 .
- the processor 220 executes instructions from the memory 225 to control the assembly 17 , and consequently the gas water heater 10 .
- the memory can also store diagnostic and trending data, which can be helpful to diagnose a potential issue before it occurs and provide more detailed information if a potential fault condition occurs.
- the controller 200 also includes signal conditioning circuitry 230 that can condition signals to and from the controller 200 .
- the temperature sensor 185 can be conditioned to a voltage within a recognizable range for the processor 220 .
- the controller 200 can include a storage device 210 , such as a super capacitor, that can provide additional or supplemental power when necessary to operate the assembly 170 .
- the assembly 170 also includes an input/output interface 240 for an operator to interact with the gas water heater 10 .
- an operator can interact with the assembly to establish a set point temperature for the water heater 10 , ignite the pilot flame 180 , and similar function normally associated with a gas water heater 10 .
- the assembly 170 can provide information to the operator, including errors or faults determined by the controller 200 .
- the water heater 10 can include dampers and/or blowers to promote operation of the gas water heater 10 .
- the gas valve 205 closes due to a possible error condition, the gas water heater 10 will not reignite until it is serviced by the user or a serviceperson.
- the user or serviceperson can read the diagnostics from the controller 200 and appropriately address the condition causing the possible error condition.
- the controller 200 can monitor a component (e.g., voltage) of the power supplied by the thermopile 190 .
- the controller 200 can monitor the voltage to determine the status of the pilot flame.
- the controller 200 can monitor the voltage to determine whether the pilot flame indicates a normal flame burn (or normal state) or an abnormal flame burn (or fault state).
- the fault state can result from an improper burn by the pilot flame.
- Example events that may cause an improper burn can include a possible lint, dust, or oil (LDO) filter blockage event, a possible flammable vapor event, a possible improper ventilation event (e.g., the blower or exhaust system not properly discharging the exhaust), and a possible overheating event.
- LDO lint, dust, or oil
- a substantial blockage of the LDO filter results in an improper burn by the pilot flame, to which the voltage value provided by the thermopile 190 is reduced.
- the controller 200 will take an action.
- the action may be providing an error output with the user interface 240 or may be providing a signal to the gas valve 205 to restrict gas to the burner 155 and/or pilot 185 .
- Other thresholds can be used to determine other abnormal flame states. It is envisioned that the various thresholds can be determined by empirical testing and that a single threshold may be used for one or more fault states.
- a nominal voltage range for the thermopile 190 is 400-800 millivolts, and consequently a range for a threshold indicating abnormal operation is between about 275 and 450 millivolts, with a preferred range of 330 and 400 millivolts. It is also envisioned that multiple thresholds can be used for a particular state—a first threshold for providing a warning and a second threshold for closing the gas valve 205 .
- the invention provides, among other things, a new and useful gas-fired heating device having a thermopile.
- a new and useful gas-fired heating device having a thermopile.
Abstract
A gas-fired heating device having a burner, a pilot to provide a pilot flame, a thermopile thermally coupled to the pilot flame and configured to generate a power in response to the pilot flame, an electrically controlled gas valve to control the flow of gas to at least one of the pilot and the burner, and a controller electrically coupled to the thermopile and the gas valve. The controller receives and is powered by the power from the thermopile. The controller initiates closing of the gas valve after a monitored component of the power, such as a voltage, traverses a threshold.
Description
- The present invention relates to heating devices, and particularly, to gas heating devices. More particularly, the invention relates to a controller used for controlling gas heating devices.
- An exemplary gas-fired heating device is a gas water heater having a burner. Gas water heaters often include a combustion chamber and an air plenum disposed below a tank, such as a water tank. A gas manifold tube, an ignition source, a thermocouple, and a pilot tube typically extend into the combustion chamber. When the temperature of the water in the tank falls below a set minimum, fuel is introduced into the combustion chamber through the gas manifold tube and a burner element. This fuel is ignited by a pilot burner flame or the ignition source, and the flame is maintained around the burner element. Air is drawn into the plenum via an air inlet, and mixes with the fuel to support combustion within the combustion chamber. The products of combustion typically flow through a flue or heat exchange tube in the water tank to heat the water by conduction.
- In one embodiment, the invention provides a new gas water heater having a burner, a pilot, a gas valve coupled to the pilot, a thermopile thermally coupled to the pilot flame and operable to generate an output voltage, and a controller powered by the thermopile and coupled to the gas valve.
- In a more specific embodiment, the controller is operable to control the gas valve based on the output voltage it receives from the thermopile. The controller includes a processor that processes a voltage value received by the controller and communicates a shutdown signal for preventing gas flow to the pilot and/or burner when an insufficient amount of voltage is outputted by the thermopile.
- In another embodiment, the invention provides a controller for a gas water heater. The gas water heater includes a burner, a pilot, an igniter, an electrically controlled gas valve, and a thermopile. The thermopile can be positioned in a standing pilot flame provided by the pilot. The standing pilot flame causes the thermopile to generate an output voltage that it used to power the controller and the electrically controlled gas valve. The controller responds to an insufficient amount of output voltage provided by the thermopile by, for example, closing the electrically controlled gas valve. The insufficient amount of output voltage can indicate the presence of a possible flammable vapor event or a possible lint, dust, or oil blockage event. Once the electrically controlled gas valve receives the shutdown signal it closes and prevents gas flow to the pilot and burner.
- In another embodiment, the invention provides a method of controlling a gas water heater. The gas water heater includes a burner, a pilot, an igniter, a thermopile, a controller, and a gas valve. The method can include detecting a possible flammable vapor event or a possible lint, dust, or oil blockage event. The thermopile produces an output voltage in response to a standing pilot flame generated by the pilot and igniter. The output voltage generated by the standing pilot flame can be between about 400 and 800 millivolts. When the thermopile outputs an insufficient amount of voltage, a voltage less than 400 millivolts, for example, the controller generates a shutdown signal and closes the gas valve. Alternatively, when the thermopile outputs too much voltage, a voltage greater than 800 millivolts, for example, the controller generates the shutdown signal and closes the gas valve. The closing of the gas valve prevents gas flow to the pilot and burner, thereby preventing any combustion from occurring.
- Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings.
-
FIG. 1 is a perspective view of a gas water heater. -
FIG. 2 is a sectional view of the bottom portion of the gas water heater. -
FIG. 3 is a block diagram of a portion of the gas water heater. - Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.
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FIGS. 1 and 2 illustrate a storage-type, gas-firedwater heater 10 that includes abase pan 15. Thebase pan 15 may be constructed of stamped metal or molded plastic, for example, and includes a generallyhorizontal bottom wall 20, avertical rise 25 having an air inlet opening 27, and an elevatedstep 30. Thewater heater 10 also includes awater tank 35,insulation 40 surrounding thetank 35, and anouter jacket 45 surrounding theinsulation 40 and thewater tank 35. Askirt 50 is supported by the base pan's elevatedstep 30 and in turn supports thewater tank 35. The elevatedstep 30 also supports theinsulation 40 andjacket 45. - In addition, the
elevated step 30 supports adivider 60 that divides the space between the bottom of thetank 35,skirt 50, and thebase pan 15 into a combustion chamber 65 (above the divider 60) and plenum 70 (below the divider 60). - A cold
water inlet tube 75 and a hotwater outlet tube 80 extend through a top wall of thewater tank 35. Aflue 85 extends through thetank 35, and water in thetank 35 surrounds theflue 85. Theflue 85 includes aninlet end 90 and anoutlet end 95. - The
combustion chamber 65 andplenum 70 space are substantially air-tightly sealed, except for the air inlet opening 27 and inletend 90 of theflue 85. Seals 105 between theskirt 50 and thetank 35 andbase pan 15 assist in sealing the space. Theseals 105 may be, for example and without limitation, fiberglass material or a high-temperature caulk material. Aradiation shield 110 sits on thedivider 60 within the sealedcombustion chamber 65 and reflects radiant heat up toward thetank 35. - A
flame arrester 115 is affixed in a sealed condition across anopening 120 in thedivider 60 such that all air flowing from theplenum 70 into thecombustion chamber 65 should flow through theflame arrester 115. Theair inlet 27,air plenum 70, and opening 120 in thedivider 60 together define an air intake for thecombustion chamber 65, and air flowing into thecombustion chamber 65 through the opening (see arrows inFIG. 2 ) 120 should flow through this air intake and theflame arrester 115. It should also be noted that the position and orientation of theflame arrester 115 are not limited to those shown in the drawings, and that substantially any construction will work provided that theflame arrester 115 acts as the gateway for the air flowing into thecombustion chamber 65 from theplenum 70. Sealingmembers 125 seal the periphery of theflame arrester 115 to thedivider 60 to reduce the likelihood of air circumventing theflame arrester 115. In alternative constructions, asingle sealing member 125 may be used to seal theflame arrester 115 with respect to thedivider 60, or if the flame arrester fits snugly against thedivider 60, no sealingmembers 125 may be needed. The flame arrester 115 prevents flame within thecombustion chamber 65 from igniting flammable vapors outside of thecombustion chamber 65. - With reference again to
FIG. 2 , theair inlet 27 is covered by a lint, dust, and oil (“LDO”)filter 130 mounted to the outer surface of thebase pan 15. The LDO filter 130 filters air flowing into theplenum 70 and reduces the likelihood that theflame arrester 115 will become occluded by lint or other debris. - A
burner 155 in thecombustion chamber 65 burns a mixture of fuel and air to create the products of combustion that flow up through theflue 85 to heat the water in thetank 35. Theburner 155 receives fuel through agas manifold 160 that extends in a sealed condition through anaccess door 165 mounted in a sealed condition over an access opening in theskirt 50. - The construction shown (illustrated in
FIGS. 1 and 2 ), employs a non-powered gas valve/thermostat assembly 170 mounted to thewater tank 10. As used herein, the term “non-powered” refers to a device that is not powered from electrical mains. However, it is envisioned that theassembly 170 can be connected to electrical mains. A gas main 175 provides fuel to the input side of theassembly 170. Theassembly 170 includes a controller 200 (FIG. 3 ) and awater temperature probe 180 that is threaded into thetank side wall 35. Connected to the output side of theassembly 170 are thegas manifold 160, apilot burner 185, athermopile 190, and anigniter 195. Thepilot burner 185,thermopile 190, andigniter 195 extend into thecombustion chamber 65 in a sealed condition through a grommet in theaccess door 165. - The
assembly 170 provides a flow of fuel to thepilot 185 to maintain a standing pilot burner flame, and this construction is therefore generally referred to as a “continuous pilot ignition” system. Theigniter 195 is used to initiate the flame on thepilot 185 without having to reach into the combustion chamber with a match. A spark is generated by theigniter 195 in response to pushing a button on theassembly 170. Thethermopile 190 provides feedback to theassembly 170 andcontroller 200 as to the presence of flame at thepilot 185. Anexemplary thermopile 190 is a model Q313 thermopile generator manufactured by Honeywell. - The
assembly 170 permits fuel to flow to theburner 155 in response to a water temperature sensor (e.g., the water temperature probe 180) indicating that the water temperature in thewater tank 35 has fallen below a selected temperature. When fuel flows to theburner 155, it is mixed with air and the mixture is ignited when it contacts the pilot burner flame. Once the water temperature sensor indicates that the water has reached the desired temperature, theassembly 170 shuts off fuel flow to theburner 155, and thewater heater 10 is in “standby mode” until the water temperature again drops to the point where theassembly 170 should again provide fuel to theburner 155. - An electrically controlled gas valve 205 (
FIG. 3 ), or more specifically, an electronically controlled gas valve is biased in the closed position with respect to thegas manifold 160 and thepilot 185. Thecontroller 200 stores some energy in astorage device 200 that allows for thegas valve 205 to be opened while igniting the pilot flame. The start up requires a user to actuate the push button of theassembly 170 which in turn opens thegas valve 205 and triggers theigniter 195. Theigniter 195 provides a spark to thepilot 185 while gas is flowing and establishes the pilot flame. Thethermopile 190 is positioned near or within the pilot flame and produces an output voltage in response to the pilot flame. The output voltage is used as a power source by thecontroller 200, which keeps the electrically controlledgas valve 205 open for thepilot flame 190. An exemplary electrically controlledgas valve 205 that can be used with the invention is a model WV8840B gas valve, manufactured by Honeywell. Before proceeding further, thegas valve 205 is shown inFIG. 3 as a single device providing fuel to both theburner 185 and thepilot 190. It should be understood, however, that thegas valve 205 can include multiple valves that are individually controlled. - The
assembly 170 is shown inFIG. 3 as including thecontroller 200. Thecontroller 200 receives a power from thethermopile 190, the power having a plurality of components (e.g., a voltage, a current). In one construction, thethermopile 190 provides a normal operation (or nominal) voltage of 400 to 800 millivolts to operate and control theassembly 170. The output voltage is recognized as being in an insufficient output voltage (state) by thecontroller 200 if the output voltage is not within this range. For example, if the voltage is greater than 800 millivolts, then the pilot flame may be burning too hot indicating a first potential issue. Similarly, if the voltage is less than 400 millivolts, the pilot flame may be burning too cool indicating a second potential issue. - In a more specific construction, the
controller 200 issues a flag or signal after the output voltage traverses a first threshold voltage (e.g., about 400 millivolts). The signal can be provided to an output device (e.g., a light emitting diode, a display, an audible alarm, etc.) of theassembly 170. Thecontroller 200 can close thegas valve 205, thereby deactivating thegas water heater 10, after the output voltage provided by thethermopile 190 traverses a second threshold voltage (e.g., about 300 millivolts). Thegas valve 205 closes in response to a signal (e.g., the application or removal of a voltage, an instruction, etc.) being sent from thecontroller 200 to thegas valve 205. - In the construction shown in
FIG. 3 , thecontroller 200 includes aprocessor 220 andmemory 225. Theprocessor 220 executes instructions from thememory 225 to control the assembly 17, and consequently thegas water heater 10. The memory can also store diagnostic and trending data, which can be helpful to diagnose a potential issue before it occurs and provide more detailed information if a potential fault condition occurs. Thecontroller 200 also includessignal conditioning circuitry 230 that can condition signals to and from thecontroller 200. For example, thetemperature sensor 185 can be conditioned to a voltage within a recognizable range for theprocessor 220. As discussed above, thecontroller 200 can include astorage device 210, such as a super capacitor, that can provide additional or supplemental power when necessary to operate theassembly 170. Theassembly 170 also includes an input/output interface 240 for an operator to interact with thegas water heater 10. For example, an operator can interact with the assembly to establish a set point temperature for thewater heater 10, ignite thepilot flame 180, and similar function normally associated with agas water heater 10. Further, theassembly 170 can provide information to the operator, including errors or faults determined by thecontroller 200. It should also be understood that thecontroller 200, and more broadly theassembly 170, can operate other elements of thewater heater 10 not shown. For example, thewater heater 10 can include dampers and/or blowers to promote operation of thegas water heater 10. - Once the
gas valve 205 closes due to a possible error condition, thegas water heater 10 will not reignite until it is serviced by the user or a serviceperson. The user or serviceperson can read the diagnostics from thecontroller 200 and appropriately address the condition causing the possible error condition. - As discussed above, the
controller 200 can monitor a component (e.g., voltage) of the power supplied by thethermopile 190. For example, thecontroller 200 can monitor the voltage to determine the status of the pilot flame. For example, thecontroller 200 can monitor the voltage to determine whether the pilot flame indicates a normal flame burn (or normal state) or an abnormal flame burn (or fault state). The fault state can result from an improper burn by the pilot flame. Example events that may cause an improper burn can include a possible lint, dust, or oil (LDO) filter blockage event, a possible flammable vapor event, a possible improper ventilation event (e.g., the blower or exhaust system not properly discharging the exhaust), and a possible overheating event. For a specific example, a substantial blockage of the LDO filter results in an improper burn by the pilot flame, to which the voltage value provided by thethermopile 190 is reduced. When the voltage value traverses the threshold indicating a possible LDO filter blockage event, thecontroller 200 will take an action. The action may be providing an error output with theuser interface 240 or may be providing a signal to thegas valve 205 to restrict gas to theburner 155 and/orpilot 185. Other thresholds can be used to determine other abnormal flame states. It is envisioned that the various thresholds can be determined by empirical testing and that a single threshold may be used for one or more fault states. In one construction, a nominal voltage range for thethermopile 190 is 400-800 millivolts, and consequently a range for a threshold indicating abnormal operation is between about 275 and 450 millivolts, with a preferred range of 330 and 400 millivolts. It is also envisioned that multiple thresholds can be used for a particular state—a first threshold for providing a warning and a second threshold for closing thegas valve 205. - Thus, the invention provides, among other things, a new and useful gas-fired heating device having a thermopile. Various features and advantages of the invention are set forth in the following claims.
Claims (21)
1. A gas water heater comprising:
a burner;
a pilot to provide a pilot flame;
a thermopile thermally coupled to the pilot flame and configured to generate a power in response to the pilot flame;
an electrically controlled gas valve to control the flow of gas to at least one of the pilot and the burner;
a controller electrically coupled to the thermopile and the gas valve, the controller to receive and be powered by the power from the thermopile, and to initiate closing of the gas valve after a monitored component of the power traverses a threshold.
2. The gas water heater of claim 1 wherein the threshold indicates an abnormal flame state for the pilot flame.
3. The gas water heater of claim 1 wherein the threshold indicates the detection of a possible flammable vapor event.
4. The gas water heater of claim 1 wherein the threshold indicates the detection of a possible lint, dust, and oil (LDO) filter blockage event.
5. The gas water heater of claim 1 wherein the threshold indicates the gas water heater has a possible improper ventilation event.
6. The gas water heater of claim 1 wherein the threshold indicates the gas water heater has a possible overheating event.
7. The gas water heater of claim 1 wherein the controller includes a processor and memory.
8. The gas water heater of claim 1 wherein the power from the thermopile includes a voltage, and wherein the monitored component includes the voltage.
9. The gas water heater of claim 8 wherein the threshold for the monitored component is between about 275 and 450 millivolts.
10. The gas water heater of claim 1 wherein the controller includes an electronic device and the gas valve includes an electronically controlled gas valve.
11. The gas water heater of claim 10 wherein the power for opening the electronically controlled gas valve originates from the power from the thermopile.
12. A safety system for use in a gas water heater including a burner, a pilot, and a gas valve, the safety circuit comprising:
a thermopile to be thermally coupled to a pilot flame of the pilot and configured to generate a power having a voltage in response to the pilot flame thermally interacting with the thermopile;
a controller electrically coupled to the thermopile and for connecting to the electronically controlled gas valve, the controller to be powered by the power from the thermopile, to monitor the voltage to determine a pilot flame status, and to control the gas valve based on the pilot flame status.
13. The safety system of claim 12 wherein the pilot flame status includes a status indicating a normal flame burn.
14. The safety system of claim 12 wherein the pilot flame status includes a status indicating a possible abnormal flame burn.
15. The safety system of claim 14 wherein the controller initiates the closing of the gas valve after the pilot flame indicates the possible abnormal flame burn.
16. The safety system of claim 14 wherein the controller determines a possible abnormal pilot flame burn when the voltage is between about 275 and 450 millivolts.
17. The safety system of claim 12 wherein the controller includes a processor and memory and wherein the memory includes diagnostic thresholds for indicating the possible abnormal flame burn.
18. The safety system of claim 12 wherein the safety circuit further includes the gas valve, and wherein the gas valve includes an electronically controlled gas valve.
19. The safety system of claim 18 wherein the power for opening the electronically controlled gas valve originates from the power from the thermopile.
20. A method for controlling a gas water heater including a burner, a pilot, a thermopile, a controller, and an electronically controlled gas valve, the method comprising:
establishing a pilot flame with the pilot;
powering the controller with a power generated by the thermopile thermally interacting with the pilot flame, the power having a voltage;
monitoring the voltage with the controller;
detecting a possible LDO filter blockage event or a possible flammable vapor event with the monitored voltage;
generating a shutdown signal with the controller in response to detecting the possible LDO filter blockage event or the possible flammable vapor event; and
closing the electronically controlled gas valve in response to the shutdown signal.
21. The method of claim 20 and further comprising opening the electronically controlled gas valve with power originating from the thermopile.
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/779,078 US20110277706A1 (en) | 2010-05-13 | 2010-05-13 | Gas-fired heating device having a thermopile |
CA2739135A CA2739135A1 (en) | 2010-05-13 | 2011-05-05 | Gas-fired heating device having a thermopile |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/779,078 US20110277706A1 (en) | 2010-05-13 | 2010-05-13 | Gas-fired heating device having a thermopile |
Publications (1)
Publication Number | Publication Date |
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US20110277706A1 true US20110277706A1 (en) | 2011-11-17 |
Family
ID=44910602
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US12/779,078 Abandoned US20110277706A1 (en) | 2010-05-13 | 2010-05-13 | Gas-fired heating device having a thermopile |
Country Status (2)
Country | Link |
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US (1) | US20110277706A1 (en) |
CA (1) | CA2739135A1 (en) |
Cited By (7)
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CN103836786A (en) * | 2012-11-27 | 2014-06-04 | 艾默生电气公司 | Water heater valves and controllers and methods of mounting the same |
US20150122200A1 (en) * | 2013-11-04 | 2015-05-07 | Jerrold M. Orlowski | Reflective pilot light viewer |
US10119726B2 (en) * | 2016-10-06 | 2018-11-06 | Honeywell International Inc. | Water heater status monitoring system |
USD873958S1 (en) * | 2018-03-02 | 2020-01-28 | Ademco Inc. | Water heater controller |
US10969143B2 (en) | 2019-06-06 | 2021-04-06 | Ademco Inc. | Method for detecting a non-closing water heater main gas valve |
US20210164652A9 (en) * | 2013-02-14 | 2021-06-03 | Clearsign Technologies Corporation | Control system and method for a burner with a distal flame holder |
US20220146149A1 (en) * | 2018-05-01 | 2022-05-12 | Ademco Inc. | Method and system for controlling an intermittent pilot water heater system |
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US20220146149A1 (en) * | 2018-05-01 | 2022-05-12 | Ademco Inc. | Method and system for controlling an intermittent pilot water heater system |
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